NGC 8200 Gas Chromatograph PDF

2101510-002 rev.
AE
NGC8206 Chromatograph
Users Manual
Intellectual Property & Copyright Notice
2009 by ABB Inc., Totalflow (Owner), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner,
regardless of any circumstances.
The original US English version of this manual shall be deemed the only valid version. Translated
versions, in any other language, shall be maintained as accurately as possible. Should any
discrepancies exist, the US English version will be considered final.
Notice: This publication is for information only. The contents are subject to change without notice and
should not be construed as a commitment, representation, warranty, or guarantee of any method,
product, or device by Owner.
Inquiries regarding this manual should be addressed to ABB Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.
TABLE OF CONTENTS
INTRODUCTION .................................................................................................... XV
Chapter Descriptions................................................................................................. xv
Getting Help .............................................................................................................. xv
Before calling..............................................................................................................xvi
Key Symbols .............................................................................................................xvi
Safety Practices and Precautions .............................................................................xvi
Safety Guidelines ...................................................................................................... xvii
Safety First ................................................................................................................ xvii
Equipment Markings................................................................................................. xviii
Grounding the Product ............................................................................................. xviii
Operating Voltage..................................................................................................... xviii
Danger From Loss of Ground................................................................................... xviii
Safe Equipment ........................................................................................................ xviii
1.0 SYSTEM DESCRIPTION ............................................................................ 11
1.1 System Overview......................................................................................... 11
1.1.1 Framework................................................................................................... 11
1.1.2 Calibration ................................................................................................... 11
1.1.3 Typical Installation ....................................................................................... 11
1.2 Processing a Sample................................................................................... 14
1.2.1 Hydrocarbons .............................................................................................. 14
1.3 Hardware System Specifications................................................................. 15
1.3.1 NGC8206 Standard Hardware Features ..................................................... 16
1.3.2 Recommended Spare Parts ........................................................................ 17
1.3.3 Cast Aluminum Enclosure ........................................................................... 17
1.3.4 Feed-through Assembly (2102026-xxx) ...................................................... 19
1.3.5 Analytical Module ...................................................................................... 110
1.3.6 Digital Controller Assembly ....................................................................... 114
1.3.7 Termination Panel ..................................................................................... 115
1.4 Grounding the NGC................................................................................... 116
1.4.1 Power Supply ............................................................................................ 116
1.4.2 Sample Probe............................................................................................ 116
1.4.3 Other Considerations................................................................................. 118
1.5 Calibration/Validation Stream .................................................................... 118
1.6 Operating Voltages and Cable Lengths..................................................... 118
1.7 Sample Transport Tubing Design.............................................................. 121
1.7.1 Tube Quality .............................................................................................. 121
1.7.2 Calculation................................................................................................. 121
1.7.3 Analysis Time ............................................................................................ 121
1.7.4 Transit Volume .......................................................................................... 121
1.7.5 Gas Volume in Transit Tubing................................................................... 122
1.7.6 Mole ........................................................................................................... 122
1.7.7 Maintaining Phase ..................................................................................... 122
1.7.8 Heat Tracing Sample Lines ....................................................................... 123
1.7.9 Tube Corrosion.......................................................................................... 123
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1.7.10 Tube Preparation .......................................................................................123
1.8 Calculating Lag Time................................................................................. 124
1.8.1 Calculations................................................................................................124
1.8.2 Calculating Using Actual Pressure.............................................................125
1.9 NGC8206 Standard Software Features..................................................... 125
1.9.1 Audit Quality Data ......................................................................................125
1.9.2 Tri-Level Security .......................................................................................125
1.9.3 Compressibility Options .............................................................................126
1.9.4 Calculation Options....................................................................................126
1.9.5 Engineering Units.......................................................................................126
1.9.6 Supported Protocols ..................................................................................126
1.10 PCCU Local Communication Options ....................................................... 127
1.11 NGC Start-Up Diagnostics ........................................................................ 127
1.11.1 Carrier Pressure Regulator Tests ..............................................................127
1.11.2 Oven Temperature Test.............................................................................128
1.11.3 Processor Control Test ..............................................................................128
1.11.4 Stream Test................................................................................................128
1.12 Start-Up Wizard ......................................................................................... 128
1.12.1 Wizard ........................................................................................................128
1.13 Historical Data ........................................................................................... 128
1.13.1 Retaining Data ...........................................................................................128
1.13.2 Analysis Cycles ..........................................................................................128
1.13.3 Stream Averages .......................................................................................129
1.13.4 Diagnostic Reports.....................................................................................129
1.13.5 Audit Logs ..................................................................................................129
1.14 TCR Sample Probe (Optional Equipment) ................................................ 129
1.14.1 Location......................................................................................................130
1.14.2 Other Considerations .................................................................................131
1.15 VGA Display (Optional Equipment) ........................................................... 131
1.16 Cold Weather Enclosure (Optional Equipment)......................................... 133
1.16.1 Enclosure ...................................................................................................133
1.16.2 Heater Options ...........................................................................................133
1.16.3 Mounting Options.......................................................................................133
1.17 Sample Conditioning Modules (Optional Equipment)................................ 134
1.17.1 Gas Types..................................................................................................134
1.17.2 Mounting Brackets .....................................................................................135
1.18 Security Seal (Optional Equipment) .......................................................... 138
1.18.1 Customer Supplied Materials.....................................................................138
1.18.2 Instructions.................................................................................................138
1.19 Optional Equipment Enclosure (Optional Equipment) ............................... 139
1.19.1 6200 Optional Equipment Enclosure .........................................................139
1.20 Power Supply Options (Optional Equipment) ............................................ 139
1.20.1 24 VDC Solar Panel Power Option ............................................................140
1.20.2 115/230 VAC UPS Power Option (24VDC Systems Only)........................141
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1.20.3 Explosion Proof Power Supply (Optional Equipment)............................... 142
2.0 INSTALLATION.......................................................................................... 21
2.1 Overview...................................................................................................... 21
2.1.1 What this Means.......................................................................................... 21
2.1.2 Organization ................................................................................................ 21
2.1.3 Locating Area for Installation....................................................................... 23
2.1.4 Installation ................................................................................................... 23
2.1.5 Pipe Mount .................................................................................................. 23
2.1.6 Stand Alone ................................................................................................. 24
2.1.7 Wall Shelf .................................................................................................... 24
2.1.8 Cold Weather Enclosure.............................................................................. 25
2.2 Unpacking and Inspection ........................................................................... 26
2.2.1 Shipping Carton........................................................................................... 26
2.2.2 Unpacking.................................................................................................... 26
2.2.3 Bill of Lading ................................................................................................ 26
2.2.4 Inspection .................................................................................................... 26
2.2.5 Damaged Components................................................................................ 26
2.3 Sample Probe Installation............................................................................ 27
2.3.1 Materials ...................................................................................................... 27
2.3.2 Instructions .................................................................................................. 27
2.4 Stand Alone Installation............................................................................... 28
2.4.1 Material Not Supplied .................................................................................. 28
2.4.2 Instructions .................................................................................................. 29
2.5 Freestanding CWE Installation .................................................................... 29
2.5.1 Materials ...................................................................................................... 29
2.5.2 Instructions .................................................................................................. 29
2.6 Pipe Mounted CWE Mounting Kit .............................................................. 211
2.6.1 Materials .................................................................................................... 211
2.6.2 Instructions ................................................................................................ 211
2.7 Optional Support Leg Installation .............................................................. 213
2.7.1 Materials .................................................................................................... 213
2.7.2 Instructions ................................................................................................ 214
2.8 Pipe Saddle Installation ............................................................................. 214
2.8.1 Material Not Supplied ................................................................................ 215
2.8.2 Instructions ................................................................................................ 215
2.9 Shelf Installation ........................................................................................ 215
2.9.1 Materials .................................................................................................... 216
2.9.2 Instructions ................................................................................................ 216
2.10 Cold Weather Enclosure (CWE) Mounting Plate....................................... 217
2.10.1 Materials .................................................................................................... 217
2.10.2 Instructions ................................................................................................ 217
2.11 NGC Installation ........................................................................................ 218
2.11.1 Materials .................................................................................................... 218
2.11.2 Instructions ................................................................................................ 219
2.12 Sample Conditioning Module Installation .................................................. 220
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2.12.1 Materials.....................................................................................................220
2.12.2 Mounting Kits .............................................................................................220
2.12.3 Instructions.................................................................................................220
2.13 Sample Line Connections ......................................................................... 221
2.13.1 Materials.....................................................................................................221
2.13.2 Instructions.................................................................................................222
2.14 Sample Line(s) to NGC Inside of Cold Weather Enclosure....................... 223
2.14.1 Materials.....................................................................................................223
2.14.2 Instructions.................................................................................................223
2.15 CWE Optional Pwr/Comm Outlet Box Assembly....................................... 224
2.15.1 Materials.....................................................................................................224
2.15.2 Instructions.................................................................................................225
2.16 Carrier/Calibration Bottle Rack Installation on Meter Run ......................... 231
2.16.1 Instructions.................................................................................................231
2.17 CWE Carrier Gas Bottle Rack Installation ................................................. 231
2.17.1 Materials.....................................................................................................231
2.17.2 Instructions.................................................................................................232
2.18 Carrier Gas Regulator with Low Pressure Switch Installation ................... 233
2.18.1 Materials.....................................................................................................233
2.18.2 Instructions.................................................................................................233
2.19 CWE Calibration Gas Bottle Installation .................................................... 235
2.19.1 Materials.....................................................................................................235
2.19.2 Instructions.................................................................................................235
2.20 Calibration Gas Regulator - Low Pressure Switch Installation .................. 236
2.20.1 Materials.....................................................................................................236
2.20.2 Instructions.................................................................................................236
2.21 Carrier Gas and Calibration Gas Connections .......................................... 237
2.21.1 Materials.....................................................................................................237
2.21.2 Instructions.................................................................................................238
2.22 Vent Lines Connections ............................................................................ 239
2.22.1 Materials.....................................................................................................239
2.22.2 Instructions.................................................................................................239
2.23 CWE Optional Catalytic Heater Installation ............................................... 240
2.23.1 Materials.....................................................................................................241
2.23.2 Instructions.................................................................................................241
2.24 CWE Optional Electric Heater Installation ................................................. 244
2.24.1 Materials.....................................................................................................244
2.24.2 Instructions.................................................................................................245
2.25 Optional Equipment Enclosure Installation................................................ 246
2.25.3 6800 Enclosure ..........................................................................................246
2.25.4 Location......................................................................................................247
2.25.5 Pipe Mount Instructions .............................................................................247
2.25.6 Wall Mount .................................................................................................249
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2.26 115/230 VAC UPS Power Supply (24 VDC Systems) ............................... 251
2.26.1 Instructions ................................................................................................ 251
2.27 115/230 VAC to 12 VDC Explosion Proof Power Supply Installation ........ 252
2.27.1 Customer Supplied Materials .................................................................... 252
2.27.2 Instructions ................................................................................................ 253
2.28 110/240 VAC to 12/24 VDC Power Supply Installation ............................. 254
2.28.1 Instructions ................................................................................................ 256
2.29 24 VDC to 12 VDC Power Converter ........................................................ 257
2.29.1 Instructions ................................................................................................ 257
2.30 Battery Pack Installation ............................................................................ 258
2.30.1 Instructions ................................................................................................ 259
2.31 Solar Panel Installation.............................................................................. 260
2.31.1 Materials Supplied ..................................................................................... 261
2.31.2 Material not Supplied................................................................................. 261
2.31.3 Instructions ................................................................................................ 261
2.32 Solar Power Pack ...................................................................................... 262
2.32.1 Instructions ................................................................................................ 262
2.33 DC Power Installation ................................................................................ 263
2.33.1 Instructions ................................................................................................ 263
2.34 Remote Communication Installation.......................................................... 264
3.0 NGC8206 STARTUP .................................................................................. 31
3.1 PCCU32 Installation and Setup................................................................... 31
3.1.1 Software Installation Instructions................................................................. 31
3.2 Ethernet Installation and Setup ................................................................... 32
3.2.1 TCP/IP Network Connection ....................................................................... 33
3.2.2 TCP/IP Local Connection ............................................................................ 34
3.3 Connecting to NGC8206s Local Port.......................................................... 35
3.3.1 Communicate Instructions ........................................................................... 35
3.4 NGC Diagnostics ......................................................................................... 37
3.5 NGC Start-Up Wizard .................................................................................. 37
3.5.1 Station Setup Instructions ........................................................................... 38
3.5.2 Stream Setup Instructions ........................................................................... 38
3.5.3 Calibration Setup Instructions ..................................................................... 39
3.5.4 Diagnostics ................................................................................................ 310
3.5.5 Update Configuration................................................................................. 310
3.5.6 Analyze Calibration Stream....................................................................... 310
3.5.7 Start-up Completion................................................................................... 311
3.6 Calibrating the NGC .................................................................................. 311
3.6.1 Instructions ................................................................................................ 312
3.7 Security System......................................................................................... 313
3.7.1 Security Code ............................................................................................ 313
3.7.2 Hardware Security ..................................................................................... 313
3.7.3 Software Security ...................................................................................... 314
3.8 Alarm Definitions ....................................................................................... 314
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4.0 MAINTENANCE .......................................................................................... 41
4.1 Overview ..................................................................................................... 41
4.1.1 Help..............................................................................................................41
4.1.2 Maintaining Cleanliness ...............................................................................41
4.1.3 How to Use This Chapter.............................................................................41
4.1.4 Returning Part(s) for Repair.........................................................................42
4.2 Spare Part Components .............................................................................. 42
4.2.1 Replacement Components ..........................................................................42
4.2.2 Replacement Parts ......................................................................................42
4.2.3 Repair Time..................................................................................................45
4.2.4 Recommended Spares ................................................................................45
4.2.5 Customer Service ........................................................................................45
4.3 Field Tool Kit ............................................................................................... 46
4.4 Visual Inspection ......................................................................................... 47
4.4.1 Inspection.....................................................................................................47
4.5 Backing Up Configuration Files (Save)........................................................ 47
4.5.1 Instructions...................................................................................................47
4.6 Restore Configuration Files ......................................................................... 48
4.6.1 Instructions...................................................................................................48
4.7 Reset Procedures........................................................................................ 48
4.7.1 Warm Start Instructions ...............................................................................48
4.7.2 Cold Start Instructions..................................................................................49
4.8 Restore Factory Defaults........................................................................... 410
4.8.1 Instructions.................................................................................................410
4.9 Lithium Battery Status ............................................................................... 411
4.9.1 Instructions.................................................................................................411
4.10 Changing NGC Clock ................................................................................ 411
4.10.1 Clock Change Not Crossing a Log Period Boundary.................................412
4.10.2 Forward Clock Change Crossing a Log Period Boundary.........................412
4.10.3 Backward Clock Change Crossing a Log Period Boundary ......................412
4.11 Replacing Calibration or Carrier Gas Bottle(s) .......................................... 412
4.11.1 Instructions.................................................................................................412
4.12 Removing Digital Controller Assembly ...................................................... 413
4.12.1 Instructions.................................................................................................413
4.13 Replacing Digital Controller Complete Assembly ...................................... 414
4.13.1 Instructions.................................................................................................414
4.14 Replacing Analytical Module ..................................................................... 415
4.14.1 Instructions.................................................................................................416
4.15 Replacing GC Module ............................................................................... 418
4.15.1 Instructions.................................................................................................418
4.16 Replacing Termination Panel .................................................................... 421
4.16.1 Instructions.................................................................................................421
4.17 Replacing Feed-through Assembly ........................................................... 423
4.17.1 Instructions.................................................................................................423
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4.18 Replacing Lithium Battery.......................................................................... 425
4.18.1 Instructions ................................................................................................ 425
4.19 Replacing Frit Filters.................................................................................. 426
4.19.1 Instructions ................................................................................................ 426
4.20 Replacing Feed-through Interface Gasket................................................. 428
4.20.1 Instructions ................................................................................................ 428
4.21 Replacing Feed-through Manifold Gasket ................................................. 428
4.21.1 Instructions ................................................................................................ 429
4.22 Replacing Termination Panel to Digital Controller Cable .......................... 430
4.22.1 Instructions ................................................................................................ 430
4.23 Replacing Analytical Processor to Termination Panel Cable .................... 432
4.23.1 Instructions ................................................................................................ 432
5.0 TROUBLESHOOTING................................................................................ 51
5.1 Overview...................................................................................................... 51
5.1.1 Troubleshooting Support ............................................................................. 51
5.1.2 Getting Started ............................................................................................ 51
5.2 Start-Up Diagnostic Troubleshooting........................................................... 53
5.2.1 Status........................................................................................................... 53
5.2.2 Carrier Pressure Regulator Test ................................................................. 53
5.2.3 Oven Temperature Test .............................................................................. 55
5.2.4 Processor Control Test................................................................................ 56
5.2.5 Stream Test ................................................................................................. 56
5.3 Troubleshooting Alarms............................................................................... 57
5.3.1 Operators..................................................................................................... 58
5.3.2 Alarm Severity ............................................................................................. 59
5.3.3 Pressure Regulator 1 or 2 Alarm................................................................. 59
5.3.4 Sample Pressure Alarm............................................................................. 510
5.3.5 Oven Temperature Error Alarm................................................................. 511
5.3.6 No Stream Valve Selected ........................................................................ 512
5.3.7 Digital-Analog Board Communication Error Alarm.................................... 513
5.3.8 Calculation Error Alarm ............................................................................. 513
5.3.9 Calibration Un-Normalized Error Alarm..................................................... 514
5.3.10 Stream Sequence Error Alarm .................................................................. 515
5.3.11 Calibration CV Percent Error Alarm .......................................................... 515
5.3.12 Calibration RF Percent Error Alarm........................................................... 516
5.3.13 Enclosure Temperature Alarm .................................................................. 517
5.3.14 Power Supply Alarm .................................................................................. 518
5.3.15 Low Carrier Gas Bottle (DI1) Alarm........................................................... 518
5.3.16 Low Cal Gas Bottle (DI2) Alarm ................................................................ 519
5.3.17 GCM Processing Error Alarm.................................................................... 519
5.3.18 Bad Bead Alarm ........................................................................................ 520
5.3.19 No Pilot Valve Change Detected Alarm .................................................... 520
5.3.20 Sample Flow Detection Alarm ................................................................... 520
5.3.21 CPU Loading Alarm................................................................................... 521
5.3.22 System Memory Available Alarm .............................................................. 521
5.3.23 RAM File Available Alarm.......................................................................... 522
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5.3.24 FLASH File Available Alarm.......................................................................522
5.3.25 Missing Peak-Calibration Not Used ...........................................................522
5.3.26 Stream Un-Normalized Total .....................................................................523
5.4 Alarm Troubleshooting Tests .................................................................... 524
5.4.1 Sample Vent Pressure Test .......................................................................524
5.4.2 Column Vent Pressure Test.......................................................................524
5.4.3 Sample Pressure Test ...............................................................................525
5.4.4 Feed-through Assembly Blockage Test.....................................................525
5.4.5 Temperature Sensor Test ..........................................................................525
5.4.6 Abnormal Calibration Gas Depletion .........................................................526
5.5 Power Troubleshooting ............................................................................. 526
5.5.1 Overview ....................................................................................................526
5.5.2 Power Supply Voltage Test........................................................................528
5.5.3 Equipment Isolation Test ...........................................................................528
5.5.4 NGC Module Isolation Test........................................................................529
5.5.5 Charger Circuit Test...................................................................................530
5.5.6 Solar Panel Troubleshooting Test..............................................................531
5.5.7 AC Charger/Power Supply Troubleshooting Test......................................532
5.6 Troubleshooting Communications ............................................................. 533
5.6.1 Communication ..........................................................................................534
5.6.2 Setting Up Communication ........................................................................534
5.6.3 Transceiver Supply Voltage Test ...............................................................536
5.6.4 12 VDC Communication Supply Voltage Test ...........................................536
5.6.5 Transceiver Check .....................................................................................537
5.6.6 RS-232 Communication Test.....................................................................537
5.6.7 RS-485 Communications ...........................................................................538
5.6.8 RS-485 Communication Test.....................................................................539
APPENDIX A MODBUS REGISTERS....................................................... A1
APPENDIX B TOTALFLOW DEFINITIONS AND ACRONYMS .............. B1
APPENDIX C DRAWINGS ........................................................................ C1
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TABLE OF FIGURES
Figure 11 Typical Single Stream Installation .................................................................................... 12
Figure 12 Typical Multi-Stream Installation ...................................................................................... 13
Figure 13 Modular Design NGC8206 ............................................................................................... 16
Figure 14 NGC8206 Enclosure ........................................................................................................ 18
Figure 15 NGC8206 Enclosure Left Side ......................................................................................... 18
Figure 16 NGC8206 Enclosure Right Side....................................................................................... 19
Figure 17 NGC8206 Enclosure Underside....................................................................................... 19
Figure 18 NGC Feed-through Assembly (2102026-xxx) ................................................................ 110
Figure 19 Analytical Module ........................................................................................................... 111
Figure 110 Manifold Assembly ....................................................................................................... 112
Figure 111 Analytical Processor Assembly .................................................................................... 113
Figure 112 GC Module Assembly................................................................................................... 114
Figure 113 Digital Controller Assembly with Optional Display ....................................................... 115
Figure 114 Termination Panel ........................................................................................................ 116
Figure 115 NGC Grounding Considerations .................................................................................. 117
Figure 116 Heat Tracing Sample Line............................................................................................ 123
Figure 117 Typical Sample Installation Diagram............................................................................ 124
Figure 118 Temperature Compensated Regulator With Sample Probe ........................................ 130
Figure 119 Optional NGC VGA Display Screen ............................................................................. 132
Figure 120 NGC8200 Cold Weather Enclosure Installation w/ Catalytic Heater ........................... 133
Figure 121 Available Sample Conditioning Modules...................................................................... 134
Figure 122 Single Stream Sample Conditioning Assembly............................................................ 136
Figure 123 Multiple Stream Sample Conditioning Assembly ......................................................... 136
Figure 124 Single Stream Conditioning Module Dimensions......................................................... 137
Figure 125 Multiple Stream Conditioning Module Dimensions ...................................................... 137
Figure 126 NGC End Cap Tabs for Security Seal.......................................................................... 138
Figure 127 Security Wire w/ Seal ................................................................................................... 138
Figure 128 6800 Enclosure with 24 VDC Solar Panel Power Supply Option ................................ 140
Figure 129 6800 Enclosure with 115/230 VAC UPS Power Option ............................................... 141
Figure 130 Explosion Proof AC Power Supply............................................................................... 142
Figure 21 Basic Meter Run Installation ............................................................................................ 22
Figure 22 Typical Wall Shelf Mount Installation ............................................................................... 22
Figure 23 Typical Cold Weather Enclosure with Electrical Heater................................................... 23
Figure 24 Sample Probe................................................................................................................... 28
Figure 25 Sample Probe Insertion.................................................................................................... 28
Figure 26 Typical CWE Stand Mount Installation........................................................................... 210
Figure 27 CWE Mounting Hardware............................................................................................... 210
Figure 28 Mounting Brackets.......................................................................................................... 211
Figure 29 Mounting Hardware Installation...................................................................................... 212
Figure 210 Adjustment Assembly................................................................................................... 212
Figure 211 Pipe Mount Installation ................................................................................................. 213
Figure 212 Chain Retainer Lock..................................................................................................... 213
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Figure 213 Optional Support Leg Overview....................................................................................214
Figure 214 Typical Pipe Saddle Installation....................................................................................215
Figure 215 Shelf Installation ...........................................................................................................216
Figure 216 NGC Mounting Plate.....................................................................................................217
Figure 217 Cold Weather Enclosure Interior...................................................................................218
Figure 218 NGC Mounting ..............................................................................................................219
Figure 219 NGC Optional Mounting Flange Pipe ...........................................................................219
Figure 220 Sample Conditioning Module Bracket ..........................................................................221
Figure 221 Sample System Mounting Kits......................................................................................221
Figure 222 Sample Conditioning Module Installation .....................................................................222
Figure 223 Sample Boot .................................................................................................................224
Figure 224 CWE Access Panel Removed ......................................................................................225
Figure 225 Power Communications Outlet Box Assembly .............................................................226
Figure 226 Assembled Power/Communication Assembly ..............................................................227
Figure 227 Power Wiring Diagram..................................................................................................227
Figure 228 Suggested RS-232 Wiring Instructions.........................................................................229
Figure 231 Carrier/Calibration Gas Bottle Rack Installation ...........................................................231
Figure 232 Dual Bottle Rack Assembly ..........................................................................................232
Figure 233 Dual Bottle Rack Installation.........................................................................................233
Figure 234 Carrier Gas Pressure Regulator with Relief Valve .......................................................234
Figure 235 Carrier Gas Low Pressure Switch Wiring Instruction....................................................234
Figure 236 Calibration Bottle Location............................................................................................235
Figure 237 Calibration Gas Pressure Regulator with Relief Valve .................................................236
Figure 238 Calibration Blend Low Pressure Switch Wiring Instruction...........................................237
Figure 239 Carrier and Calibration Gas Connections.....................................................................238
Figure 240 Vent Line Connections on Feed-through Assembly .....................................................240
Figure 241 Catalytic Heater Option in Cold Weather Enclosure.....................................................241
Figure 242 Catalytic Heater Assembly............................................................................................242
Figure 243 Thermostat Assembly Installed.....................................................................................242
Figure 244 Regulator Assembly Installed .......................................................................................243
Figure 245 Temperature Probe Installation ....................................................................................243
Figure 246 Electrical Pre-Heater Wiring Instructions......................................................................244
Figure 247 Electrical Heater Installed in CWE................................................................................245
Figure 248 Electric Heater Option Wiring Instructions....................................................................245
Figure 249 6200 Enclosure Pipe Mounting Installation ..................................................................247
Figure 252 6200 Enclosure Wall Mounted Installation ...................................................................249
Figure 255 115/230 VAC UPS Power Supply Option .....................................................................252
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Figure 256 Explosion Proof AC Power Supply Top/Front Dimensions .......................................... 253
Figure 257 Explosion Proof AC Power Supply Side Dimensions................................................... 253
Figure 258 Explosion Proof AC Power Supply Wiring Instructions ................................................ 254
Figure 259 6200 Optional Equipment Enclosure with Power Supply............................................. 255
Figure 260 6700 Optional Equipment Enclosure with Power Supply............................................. 255
Figure 261 AC/DC Converter Wiring Instructions........................................................................... 256
Figure 262 24 VDC/12 VDC Power Supply Converter................................................................... 258
Figure 263 Optional 6800 Enclosure with Battery Pack................................................................. 259
Figure 264 24 VDC Dual Battery Pack Cable ................................................................................ 259
Figure 265 Battery Pack with AC Power Supply Wiring Instructions ............................................. 260
Figure 266 Typical Solar Panel Installation .................................................................................... 261
Figure 267 24 VDC Solar Panel Power Supply.............................................................................. 263
Figure 31 Ethernet Connections....................................................................................................... 32
Figure 32 Ethernet Cable-Typical..................................................................................................... 33
Figure 33 Ethernet Cable-Cross-Over.............................................................................................. 34
Figure 34 MMI Communication Cables ............................................................................................ 36
Figure 35 Typical Chromatograph for Chrom-1 (Heavies) ............................................................. 312
Figure 36 Typical Chromatograph for Chrom-2 (Lights)................................................................. 313
Figure 41 NGC8206 Overall View .................................................................................................... 43
Figure 42 Analytical Module, Exploded ............................................................................................ 44
Figure 43 Feed Through Assembly, Exploded ................................................................................. 44
Figure 44 Digital Controller Complete Assembly............................................................................ 410
Figure 45 Digital Controller Board .................................................................................................. 414
Figure 46 Analytical Module ........................................................................................................... 417
Figure 47 Analytical Processor Board ............................................................................................ 417
Figure 48 GC Module, Exploded View ........................................................................................... 420
Figure 49 Termination Panel .......................................................................................................... 422
Figure 410 Feed-Through Assembly.............................................................................................. 424
Figure 411 Primary Component Side Digital Controller Board....................................................... 426
Figure 412 Feed-through Assembly, Exploded View ..................................................................... 427
Figure 51 Troubleshooting Flowchart............................................................................................... 52
Figure 52 Power Troubleshooting Flowchart.................................................................................. 527
Figure 53 Solar Panel Wiring Instructions ...................................................................................... 532
Figure 54 AC Charger/Power Supply Wiring.................................................................................. 533
Figure 55 Communication Troubleshooting Flowchart................................................................... 535
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LIST OF TABLES
Table 11 Hydrocarbons .................................................................................................................... 14
Table 12 System Specifications ....................................................................................................... 15
Table 13 Calibration Gas Blend Recommended Components ...................................................... 118
Table 14 12 VDC Battery Power Supply System Maximum Cable Lengths .................................. 120
Table 15 AC Power Supply System Maximum Cable Lengths ...................................................... 120
Table 16 Internal Volume of Commonly Used Sample Transport Tubing...................................... 122
Table 17 Calculation File Settings .................................................................................................. 126
Table 18 Communication Option Comparison ............................................................................... 127
Table 19 Optional Temperature Compensated Regulator (TCR) .................................................. 130
Table 110 Sample Conditioning Module Descriptions.................................................................... 135
Table 21 Port 1 and Port 2 Pin-Outs/Terminations ........................................................................ 264
Table 31 Station Setup Screen Information ..................................................................................... 38
Table 32 Stream Setup Screens ...................................................................................................... 39
Table 33 Defaulted Alarm Definitions............................................................................................. 314
Table 41 Repair Time vs. Down Time .............................................................................................. 45
Table 42 Recommended Spare Parts .............................................................................................. 46
Table 43 Tool Requirements ............................................................................................................ 46
Table 51 NGC8200 Alarms .............................................................................................................. 58
Table 52 Alarm Severity ................................................................................................................... 59
Table 53 Specifications for Solar Panels........................................................................................ 531
Table 54 RS-232 Field Wiring on NGC Termination Panel............................................................ 537
Table 55 RS-485 Terminations....................................................................................................... 539
Table 56 RS-485 Field Wiring on NGC Termination Panel............................................................ 539
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Introduction
This manual is written to provide an experienced chromatography technician with
the requirements necessary to install, setup and operate the Totalflow Model
NGC8206 Natural Gas Chromatograph.
Each of the chapters in this manual presents information in an organized and
concise manner. Readers are able to look at the headings and get a broad picture
of the content without reading every word. Also, there are overviews at the
beginning of each chapter that provides the user with an idea of what is in the
chapter and how it fits into the overall manual.
Chapter Descriptions
The manual provides the following information:
Chapter Name Description
Provides a description of the Totalflow NGC
1 System Description
system components and specifications.
Includes unpacking and detailed procedures
2 Installation
for setup and installation.
Provides the user with a tutorial on how to get
3 Startup
a newly installed NGC system up and running.
Provides Procedures on how to remove and
4 Maintenance
replace major modules.
Provides a troubleshooting chart and
5 Troubleshooting
procedures on how to correct most problems.
Appendix Modbus Register Provides a listing of all valid Modbus
A Tables Registers.
Appendix Definitions & Provides quick access to the majority of terms
B Acronyms and abbreviations, as well as their definitions.
Appendix Provides a place to put drawings that
Drawing
C accompany a unit.
Getting Help
At Totalflow, we take pride in the on going support we provide our customers.
When purchasing a product, the user receives documentation which should
answer their questions; however, Totalflow Technical Support provides an 800
number as an added source of information.
If requiring assistance, call:
USA: (800) 442-3097 or International: 1-918-338-4880
xv
Before calling
Know the Totalflow model and serial number. Serial numbers can be found
on a plate located on each unit.
Be prepared to give the customer service representative a detailed
description of the problem.
Note any alarms or messages as they appear.
Prepare a written description of problem.
Know the software version, board and optional part numbers.
Key Symbols
The following symbols are used frequently in the manual. These are intended to
catch the users eye and draw attention to important information.
Intended to draw attention to useful information or to clarify a

statement made earlier.
Intended to draw attention to a fact that may be useful or

helpful in understanding a concept.
Intended to draw your attention to information regarding

security access to equipment and Software Security features.
Intended to draw attention to a statement that might keep the

user from making a mistake, keep them from destroying
equipment or parts, or keep them from creating a situation
that could cause personal injury if caution is not used. Please
refer to the Safety Practices and Precaution section for
additional information.
Intended to draw attention to a statement regarding the
likelihood of personal injury or fatality that could result from
improper access or techniques used while working in
hazardous locations. Please refer to the Safety Practices
and Precaution section for additional information.
Indicates procedures that are only valid if system design

includes a Cold Weather Enclosure.
Safety Practices and Precautions

This manual contains information and warnings which have to be followed by the
user to ensure safe operation and to retain the product in a safe condition.
Installation, maintenance and repairs should only be performed by a trained and
qualified technician. Please refer to Certification Drawings shipped with this unit
for specific guidelines. Extra copies of the certification drawings, referenced on the
unit name tag, can be obtained, free of charge, by contacting Totalflow Technical
Support at the number listed in the Getting Help section.
xvi
Safety Guidelines
DO NOT open the equipment to perform any adjustments, measurements,
maintenance, parts replacement or repairs until all external power supplies
have been disconnected.
Only a properly trained technician should work on any equipment with power
still applied.
When opening covers or removing parts, exercise extreme care as live parts
or connections can be exposed.
Installation and maintenance must be performed by person(s) qualified for
the type and area of installation according to national and local codes.
Capacitors in the equipment can still be charged even after the unit has been
disconnected from all power supplies.
Safety First
Various statements in this manual, identified as conditions or practices that could

result in equipment damage, personal injury or loss of life, are highlighted using
the following icons:
Exercise caution while performing this task. Carelessness could
result in damage to the equipment, other property and personal
injury.
STOP. Do not proceed without first verifying that a hazardous
condition does not exist. This task may not be undertaken until
proper protection has been accomplished, or the hazardous
condition has been removed. Personal injury or fatality could
result. Examples of these warnings include:
Removal of enclosure cover(s) in a hazardous location must follow
guidelines stipulated in the certification drawings shipped with this
unit.
If the unit is installed or to be installed in a hazardous location, the
technician must follow the guidelines stipulated in the certification
drawings shipped with this unit.
Access to a unit via a PCCU cable in a hazardous location must
follow guidelines stipulated in the certification drawings shipped
with this unit.
Connecting or disconnecting equipment in a hazardous location for
installation or maintenance of electric components must follow
guidelines stipulated in the certification drawings shipped with this
unit.
DANGER indicates a personal injury hazard immediately
accessible as one reads the markings.
CAUTION indicates a personal injury hazard not immediately
accessible as one reads the markings or a hazard to property,
including the equipment itself.
xvii
Equipment Markings
Protective ground (earth) terminal.
Grounding the Product
If a grounding conductor is required, it should be connected to the grounding

terminal before any other connections are made.
Operating Voltage
Before switching on the power, check that the operating voltage listed on the
equipment agrees with the power being connected to the equipment.
Danger From Loss of Ground
A grounding conductor may or may not be required depending on the hazardous

classification. If required, any interruption of the grounding conductor inside or
outside the equipment or loose connection of the grounding conductor can result
in a dangerous unit. Intentional interruption of the grounding conductor is not
permitted.
Safe Equipment
If it is determined that the equipment cannot be operated safety, it should be taken

out of operation and secured against unintentional usage.
xviii
1.0 SYSTEM DESCRIPTION
1.1 System Overview

This chapter introduces the user to the Totalflow Model NGC8206 Series Natural
Gas Chromatograph (NGC). The NGC is designed to continually analyze natural
gas streams, on-site, determine composition, calorific value and store the analysis
information. It is designed for natural gas streams, 800 to 1500 Btu/scf (29.8 to
55.9 Megajoules/meter3) with less than 100 PPM H2S.
The unit is a fully functional gas chromatograph for pipeline quality natural gas
and is designed to analyze natural gas streams, dry of both hydrocarbon liquids
and water. The unit can collect and retain analysis information for one to four
independent sample streams. Applicable installations include: Transmission,
Distribution, Custody Transfer with Metrology quality results, Production, Gas
Gathering and End User Gas Markets.
1.1.1 Framework
Based on ABB Totalflow XSeries technology, the NGC features a common

platform that combines the expandable framework of the XSeries equipment with
the capabilities of a remote gas chromatograph. This expandability allows the
NGC to run other applications such as AGA-3 and AGA-7, while simultaneously
doing stream analysis. This new platform is designed for operation on Windows
CE Real Time Operating System.
1.1.2 Calibration
Once installed on the meter run, the unit can immediately calculate the calorific
value of natural gas. The user can utilize their own calibration blend to adjust the
unit to their companys standards or take advantage of various automatic
operational features by using the recommended calibration gas.
1.1.3 Typical Installation
This compact unit requires minimal installation time and is fully configured and
calibrated at the factory. A typical single stream pipeline installation includes a
sample probe, optional sample conditioning module, carrier and calibration gas
(see Figure 11). A multiple stream pipeline installation includes an installation
where sample probes may be connected to the NGC (see Figure 12).
2101510-002 rev. AE Page 11

Page 12
CARRIER GAS CALIBRATION GAS
NGC8200
DECREASE
INCREASE
D ECREASE INCREASE
SAMPLE CONDITIONING
MODULE
SAMPLE PROBE
Figure 11 Typical Single Stream Installation
2101510-002 rev. AE
STREAM 3 SAMPLE PROBE
2101510-002 rev. AE
NGC8200
I NC REASE
DE CREASE
CALIBRATION GAS
SAMPLE CONDITIONING
MODULES
Figure 12 Typical Multi-Stream Installation

CARRIER GAS
For clarity, unit is shown mounted on outside meter run. For sample line length consideration,
the unit should be mounted on middle pipe run.
Page 13
1.2 Processing a Sample
A natural gas sample is extracted from the pipeline, processed for particulate
removal and phase integrity by the sample conditioning module (optional as
required), transported to the NGC and injected onto the chromatographic columns
where component separation occurs.
The NGC analyzes each sample, utilizing established chromatographic
techniques. The resulting information consists of mole percent values for each
component. These values are used to perform energy calculations. Calculated
values include: gas compressibility, real relative density, Btu/CV value, liquid
GPM, Wobbe index, methane number and several other optional calculated
values. Gas compressibility selections include NX-19, AGA-8 detail, single virial
summation factor, ISO summation factor and none (a factor of one is used).
The processed sample is then vented with the carrier gas and results are stored in
memory and communicated to other devices, as needed. All of these values as
well as composition are available on various Modbus communication protocols.
1.2.1 Hydrocarbons
To further define the natural gas components, Table 11 gives additional details
for each hydrocarbon. Among the key information is the boiling point of the
component. The boiling point of each component correlates to the order each
component will exit the column.
Table 11 Hydrocarbons
Molecular Common Abbreviation Component Boiling Point

Formula
C1H4 C1 Methane -161.6
C2H4 C2= Ethylene -103.75
C2H6 C2 Ethane -88.65
C3H6 C3= Propylene -47.65
C3H8 C3 Propane -42.05
C4H10 IC4 Isobutane -11.65
C4H8 C4= Butylene -6.95
C4H10 C4 Butane -.45
C5H12 NeoC5 Neopentane 9.85
C5H12 IC5 Isopentane 27.85
C5H12 C5 Pentane 34.85
C6H14 C6 Hexane 68.85
C7H16 C7 Heptane 97.85
C8H18 C8 Octane 125.55
C9H20 C9 Nonane 150.95
C10H22 C10 Decane 173.95
Page 14 2101510-002 rev. AE

1.3 Hardware System Specifications
Table 12 System Specifications
12 VDC 24 VDC
No. Aux. Heater W/Aux. Heater No Aux. Heater W/Aux. Heater
Supply Voltage 10.516 VDC 10.516 VDC 2128 VDC 2128 VDC
Recommended AC
Power Supply 14.5V 14.5V 25V 25V
Maximum
Instantaneous
Current1 4 Amp 8.2 Amp 2.2Amp 5.2Amp
Avg. Power
Consumption After
Startup2 Up to 7 Watts Up to 53 Watts Up to 7 Watts Up to 64 Watts
Environment Storage -22F to +140F (-30 to 60C)
Temperature
Normal Operation 0F to +131F (-18C to 55C)
W/Cold Weather Enclosure -40F to +131F (-40 to 55C)
Repeatability 0.125 Btu @ 1,000 Btu (0.0125%) ambient;
0.25 Btu @ 1,000 Btu (0.025%) over temp. range of 0131F (-18 to 55C)
Helium Carrier Consumption rate: 12 ml/minute typical to 20 ml/minute maximum.
Medium 800 to 1500 Btu per Standard Cubic Foot (29.8 to 44.6 megajoules/meter3) with less
than 100 PPM H2S
Analysis Time Approx. 5 minutes; interval between cycles is adjustable.
Calibration/Validation Up to 2 dedicated (reduces sample stream for each dedicated calibration streams).
Streams Must use dedicated stream(s) for Auto-Cal feature.
Sample Streams Up to 4 (with manual calibration streams)
Construction NEMA/Type 4X (IP56)
Aluminum Alloy With White Polyester Powder Coating.
Explosion Proof, see Specification Sheet for certifications.
Installation Time Requires 2-3 hours for installation, minimum 8 hours run time for repeatability.
Mounting Pipe Run, Free-Standing Pipe, Shelf and Cold Weather Enclosure.
8206 Dimension Width Height Depth Weight
US 9.5 8.82 15.64 29 lbs.
Metric 241.3 mm 224.0 mm 397.3 mm 10.8 kg
1 Usually experienced at startup. Use this for power supply sizing requirements (includes approx. 20% buffer and is calculated
for maximum allowable power supply voltages).
2 At Recommended AC Power Supply Voltage. Highly temperature dependant, with Feed-through Heater operating
continuously. Usually occurs at only the coldest ambient operating temperature, i.e. 0F (-18C).
2101510-002 rev. AE Page 15

1.3.1 NGC8206 Standard Hardware Features
The Totalflow NGC (Natural Gas Chromatograph) features a rugged, field ready
design. Installation, startup and troubleshooting times have been greatly reduced
due to these user friendly hardware features:
Enclosure compact design
Cast aluminum housing with six exterior hubs
Powder coating
Weatherproof construction
Modular design (See Figure 13)
Digital controller assembly
Analytical module with compact design and single bolt replacement
Feed-through assembly with flame path arrestors
Termination panel
State of the art electronics
32-bit digital controlling electronics (i.e., no analog Control loops)
Low power operation
Dual digital carrier pressure regulation
Digital temperature control
Digital detector electronics
Low EMI/RFI Design
Operates on Windows CE
Auto-start with diagnostics
Factory calibrated
Figure 13 Modular Design NGC8206
Page 16 2101510-002 rev. AE

1.3.2 Recommended Spare Parts
Totalflow has provided a recommended spares list for the NGC8206 product line.
Consideration was given to the cost of the repair time and the cost of stocking
repair parts. The NGC8206s modular design is uniquely suited to quick repair
times. All the modules are easily replaced in a short time. A more comprehensive
discussion of recommended spare parts can be found in Chapter 4-Maintenance.
1.3.3 Cast Aluminum Enclosure
The custom designed, explosion proof enclosure consists of a cylindrical shaped

cast aluminum housing, powder coated, with front and rear end caps for access to
internal components. Figure 14 through Figure 17 shows the outline dimensions
of the NGC.
The end caps have precision engineered threading and are susceptible to damage
if treated roughly. Enclosure and all fittings, including feed-through, MMI
connection and breather are tested to Nema/Type 4X. Unauthorized removal of
the end caps are protected with a 1/16 hex socket set screw on each end cap.
This enclosure may be pipe mounted on meter run using a pipe saddle, stand
alone pipe mounted, shelf mounted or optionally mounted in a cold weather
enclosure. Unit may be directionally positioned using 1/8 hex socket set screws
located in the neck of the enclosure.
1.3.3.1 Exterior Hubs

The unit enclosure features six exterior hubs:
Gas feed-through assembly
Explosion proof local MMI port
Four miscellaneous hubs, including:
Communication hub
Power hub
Digital input/output wire hub
Undefined hub
2101510-002 rev. AE Page 17

Figure 14 NGC8206 Enclosure
Figure 15 NGC8206 Enclosure Left Side
Page 18 2101510-002 rev. AE

Figure 16 NGC8206 Enclosure Right Side
Figure 17 NGC8206 Enclosure Underside
1.3.4 Feed-through Assembly (2102026-xxx)
Independent sample streams are connected to the NGC directly to the feed-
through assembly (see Figure 18), or through an optionally installed sample
conditioning module. The feed-through assembly also serves as the connection
2101510-002 rev. AE Page 19

for carrier gas and calibration streams, and contains the vents for sample and
column gases. The feed-through assembly comes in three configurations:
Without auxiliary heater
With 12 VDC auxiliary heater
With 24 VDC auxiliary heater
Assemblies with the auxiliary heater feature a heater with a temperature sensor
cable which makes connection to the analytical module and is replaceable. Please
note that this cable comes in two configurations: 12 VDC and 24 VDC.
1.3.4.1 Inlets
All inlets have an internal, replaceable, 0.5 micron filters. Available inlets are:
14 sample stream inputs, calibration blend streams
13 sample streams with 1 dedicated auto cal stream, or
12 sample streams with 12 dedicated auto cal streams, or
14 sample streams with 12 manual calibration streams.
1 Carrier input stream.
Figure 18 NGC Feed-through Assembly (2102026-xxx)
The 0.5 micron Filters should NOT be considered as a

replacement for the primary filtering system. Optional sample
conditioning modules are designed for this purpose.
1.3.4.2 Vents
Feed-through assembly vents do not have filters, but require vent tubing to be
attached and routed accordingly. These are:
2 column vents (CV1 and CV2)
1 sample vent (S1, S2, S3 and S4)
1 gauge port vent (GPV)
1.3.5 Analytical Module
The modular design of the analytical module is enhanced by the single bolt
removal feature. This assembly is comprised of the manifold and analytical
Page 110 2101510-002 rev. AE

processor. These parts are not field replaceable. The GC module is an important
part of the analytical module, but is field replaceable. More discussion will follow.
The analytical module comes in two configurations: 12 VDC and 24 VDC.
Of the subassemblies that comprise the analytical module, GC module and
manifold assembly come in two configurations: 12 VDC and 24 VDC.
In Figure 19 the user can see the analytical module assembly removed from the
enclosure.
1.3.5.1 Features
High-speed serial interface to digital controller board
32-bit digital signal processor
Flash memory
Analog to digital conversion circuits
Digital oven temperature controller
Digital auxiliary heater controller (optional feed-through heater)
Dual digital pressure regulators
Sample pressure sensor
Pressure sensors (100 PSI max.)
Thermal conductivity detectors
System level voltage monitoring
Analytical processor board level temperature sensor
LED board status indicators
Figure 19 Analytical Module
2101510-002 rev. AE Page 111

1.3.5.2 Manifold Assembly
The manifold assembly is comprised of the manifold plate, heater, valves and
various cables to other major components. The manifold plate and heater maintain
constant temperature for the GC module and columns. The valve controls the
stream processing, carrier and calibrations gases. The cables complete the
information chain from the GC module to the analytical processor and the digital
controller assembly.
Figure 110 shows the manifold assembly. This is not a field replaceable part.
Figure 110 Manifold Assembly
1.3.5.3 Analytical Processor Assembly

The analytical processor board provides real-time system control and
measurement of the analytical processes within the NGC. It does this by
interfacing with all of the sensors in the GC module (and optional feed-through
temperature sensor) as well as controlling the carrier pressure regulator valves,
sample stream valves, the pilot valve and the heaters. The data generated by the
analytical processor is passed to the digital controller board via a high speed serial
interface.
The analytical processor also has two status LED's used for troubleshooting. The
red LED indicates that the board is powered on. If the board is remotely powered
down by the digital controller, or has no power, this LED is off. The yellow LED
indicates that the analytical processor's CPU has booted its program successfully
and is controlling its processes as directed by the digital controller. This LED
should be flashing at a high speed (between 20-40Hz). If this LED is off or is on
solid with no flashing, then the software in the analytical processor is not running
properly.
Figure 111 shows the analytical processor assembly. This is not a field
replaceable part.
Page 112 2101510-002 rev. AE

Figure 111 Analytical Processor Assembly
1.3.5.4 GC Module
The GC module is comprised of three parts: columns, chromatographic valve and
GC module circuit board. The valve controls the flow of gas within the system. The
columns perform the separation of the gas into component parts for analysis. The
GC module circuit board contains the sensors for the carrier pressure regulators,
the sample pressure sensor and the thermal conductivity detectors (TCD's) which
detect the different gas components as they leave the GC columns. It also
contains an EEPROM or FLASH memory for storage of calibration and
characterization information of the module and its sensors. Replacement is by
single bold removal.
Figure 112 shows the GC module with the oven wall removed.
2101510-002 rev. AE Page 113

Figure 112 GC Module Assembly
1.3.6 Digital Controller Assembly
This assembly (see Figure 113) contains the digital electronic board, mounting
assembly and, optionally, a VGA display.
The digital controller board provides control parameters to the analytical processor
board and stores and processes the data sent from the analytical processor
board. The digital controller also processes communication with other devices.
The digital electronic board features:
16 MB Pseudo Static Ram (Application), Lithium Battery backed.
32 MB NAND Flash Memory (Boot/Application/Storage)
4 MB Static CMOS Memory (Storage)
1 Secure digital Card Socket, with up to 4 GB Removable Storage optional)
Page 114 2101510-002 rev. AE

AB B
Figure 113 Digital Controller Assembly with Optional Display
1.3.7 Termination Panel
The NGC8206 termination panel acts as a connection to the outside world (see
Figure 114). It features transient protection, a voltage regulator for digital
controller, positive temperature co-efficient fuses (PTC) and many other
safeguards to protect the remainder of the system from electrical damage. All
outside communications and I/O are channeled through this board. It is designed
to be a low cost, field replaceable maintenance solution and is designed to
operate on either 12 VDC or 24 VDC.
1.3.7.1 Features
Transient protection
EMI/RFI protection
PTC fuses
Voltage regulator for digital controller
Dedicated local serial data interface (up to 115200 bps)
2 LED status indicators (software programmable)
1 Power monitor status indicator
1 5 VDC LED status indicator
2 DIs and 2 DOs connected to digital controller
2 remote serial ports (RS232/RS422/RS485 software selectable)
Optional Ethernet interface with 3 LED status indicators
Optional USB host and client interface
2101510-002 rev. AE Page 115

1.3.7.2 Local Interface
This local PC interface requires PCCU32 version 6.0 or higher, a laptop PC and a
MMI cable, either USB or serial RS-232. The software operates within the full
range of Windows 95,98, 2000, NT and XP utilities. Maintenance functions can
be performed by personnel with little or no knowledge of gas chromatography; see
the online Help files for more information.
PRIMARY COMPONENT SIDE SECONDARY COMPONENT SIDE
DIGITAL I/O
VOLTAGE REGULATOR LED
POWER
VOLTAGE
SECURITY SWITCH J2 REGULATOR
POWER LED
S2 J1 VR1
(-) (+) (-) (+) (-) (+) (-) (+)
UNSECURE
(-) (+)
1 2 1 2
INPUTS OUTPUTS
D1
LOCAL SERIAL DATA 5VDC ETHERNET
POWER
CONNECTION D2 RECEPTICAL J12
SERIAL PORT 2
SERIAL PORT 1 TERMINATION
TERMINATION J7
J9 J11
1 3 J3 1 3 SERIAL PORT 2
SERIAL PORT 1
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
J8 J10
J5 SECURITY
ENABLED
D12 D11 D13
S1
D3 D4
USB HOST RECEPTICAL J6 STATUS ANALYTICAL PROCESSOR
STAT CONNECTION J4
LAN
LINK
USB CLIENT RECEPTICAL
RESET
ETHERNET STATUS INDICATORS DIGITAL CONTROLLER
SECURITY CONNECTION
SWITCH STATUS
Figure 114 Termination Panel
1.4 Grounding the NGC

The NGC8206 must be properly grounded. The NGC has a grounding lug on the
mounting neck of the enclosure. This lug should be tied to a good earth ground
with no smaller than #12AWG wire. The NGC8206 cannot be connected to any
pipeline where cathodic protection exists. If the system uses cathodic protection,
the NGC must be mounted on a section of pipe that has been electrically isolated
from the cathodic currents (see Figure 115).
1.4.1 Power Supply
The power supply for the NGC should have an isolated output (i.e., the negative
side of the 12 VDC output should not be electrically connected to chassis or earth
ground). In many instances, the power supply is collocated with a radio. If the
radio is connected to the NGC8206 via RS232/485/422, the communications
should share the power ground. The communication shield should only be
connected at the NGC end. The other end should be left to float (left
unconnected).
1.4.2 Sample Probe
If the sample probe is mounted to a section of pipe where cathodic currents may
exist, the user needs to put isolators in the sample tubing between the sample
probe and the NGC. Any time that the sample probe is on a section of pipe other
than the one where the NGC is directly mounted, tubing isolators should be
employed. It is very important that probe ground and the NGC ground be at the
same potential. If this cannot be insured, tubing isolators must be used.
Page 116 2101510-002 rev. AE

Figure 115 NGC Grounding Considerations
2101510-002 rev. AE Page 117

1.4.3 Other Considerations
If other devices are to be powered from the same isolated power supply that is
powering the NGC, be careful to avoid any ground loops. The various devices
should be connected in a star configuration. It is also important that any additional
powered devices be able to handle a fairly wide range of input voltages, as the
NGCs heater will draw about 4 amps (if the auxiliary heater is installed, it might be
as much as 8 amps). This load (4-8 amps) being drawn across any considerable
length of cable can result in a substantial voltage drop (Please refer to Cable
Length Power Specifications table). The resulting lower input voltage to the
additional device could effect its operation. Input voltage excursions fluctuate with
the toggling of the NGCs heater(s). The heater(s) are turning on and off in an
effort to maintain a very constant internal temperature for the NGCs GC module.
In an office environment, insure that a good earth ground is established to the
NGC8206. In an office situation, it is easy to not have the NGC well grounded.
Often the third pin (ground) on the power cable is missing or has been removed.
Improper grounding can lead to erratic behavior. Be sure that the unit is properly
grounded. If the unit is not properly grounded, the user could have as much as 60
VAC (half line voltage) on the case of the equipment due to capacitive coupling
within the power supply.
1.5 Calibration/Validation Stream

On the NGC feed-through assembly, one or two of the sample streams may be
used for a calibration gas input. It is recommend that a metal diaphragm regulator
is set to 15 2 PSIG input. The recommended calibration gas component
concentrations for use with Auto Peak Find may be found in Table 13.
Table 13 Calibration Gas Blend Recommended Components
Component Abbreviation Mol % Component Abbreviation Mol %

Name Name
Nitrogen N2 2.500 Normal Butane NC4 0.300
Methane C1 89.570 Neo Pentane Neo C5 0.100
Carbon Dioxide CO2 1.000 Iso Pentane IC5 0.100
Ethane C2 5.000 Normal Pentane NC5 0.100

Hexanes and
Propane C3 1.000 C6+ 0.030
Heavier
Iso Butane IC4 0.300
1.6 Operating Voltages and Cable Lengths

The NGC is designed for connection to a 12 VDC or 24 VDC power source. The
12 volt power source must provide a minimum of 10.5 VDC to a maximum of 16
VDC at 4 amps minimum, and the 24 volt must provide a minimum of 21 VDC to a
maximum of 28 VDC at 2.2 amps. The configurations with the auxiliary feed-
through heater increase the requirements.
Adequate wire size is a function of the distance between the NGC and the DC
power supply. When running wiring from the power source to the NGC,
consideration must be given to the voltage dropped between the power source
Page 118 2101510-002 rev. AE

and the NGC. Smaller wire gauges have greater resistance and, therefore, a
greater voltage drop across the wiring. The following tables (see Table 14 and
Table 15) document multiple cable sizes and corresponding maximum cable
lengths for DC and AC installations with and without the auxiliary feed-through
assembly heater.
Additional devices connected to the NGC and requiring power (XMVs, radios, etc.)
must be factored into this calculation. Refer to their technical specifications for the
requirements of each, or call Totalflow for help computing cable requirements for
additional loads.
For non-standard applications or other questions exist, call
Totalflow Customer Service at:
2101510-002 rev. AE Page 119

Table 14 12 VDC Battery Power Supply System Maximum Cable Lengths
Min. Batt
Model 1 1 1
Voltage Units 10 AWG 12 AWG 14 AWG 16 AWG 6 mm^2 4 mm^2 2.5 mm^2 1.5 mm^2
/Option
(V)
12 VDC NGC w/o (ft) 78.28 49.44 30.97 19.43 90.03 60.17 37.42 22.92
12.00
Feed-through heater (m) 23.86 15.07 9.44 5.92 27.44 18.34 11.41 6.99
12 VDC NGC with (ft) 38.74 24.47 15.32 9.62 44.55 29.78 18.52 11.34
12.00
Table 15 AC Power Supply System Maximum Cable Lengths
(No External Devices connected to NGC, AC Power Supply Only)

Model Recommended 1 1 1
Units 10 AWG 12 AWG 14 AWG 16 AWG 6 mm^2 4 mm^2 2.5 mm^2 1.5 mm^2
/Option PS Voltage (V)
12 VDC NGC w/o (ft) 469.67 296.64 185.81 116.61 540.20 361.03 224.55 137.54
14.50
12 VDC NGC with (ft) 232.43 146.80 91.95 57.71 267.33 178.66 111.12 68.06
14.50
24 VDC NGC w/o (ft) 809.52 511.27 320.25 200.98 931.07 622.26 387.02 237.06
25.00
24 VDC NGC with (ft) 336.97 212.83 133.31 83.66 387.57 259.03 161.10 98.68
25.00
1 This wire size may require splicing in 12AWG or 2.5mm^2 or smaller wires at each end of the cable to be able to fit screw terminals.
Page 120 2101510-002 rev. AE

1.7 Sample Transport Tubing Design
Information in this section enables the user to design the sample transport tubing
connected between the TCR sample probe and installed NGC. Minimizing
transport lag time and maintaining a single vapor phase sample are important
factors to consider when selecting transport tubing.
Lag time is the time required to purge out one volume of transport tubing and the
volume of the sample conditioning system.
1.7.1 Tube Quality
Use only good quality clean stainless steel chromatographic grade transport
tubing for carrier, calibration gas and sample lines. Use of poor quality stainless
steel tubing gives unsatisfactory results.
Do not use any type of plastic, Teflon or Teflon lined braided
steel tubing.
Transport tubing must be chromatographically clean. Tubing should be free of

hydrocarbon contamination and particle free. During cutting, fitting and deburring,
the technician should insure that no particles are allowed to remain in the tubing.
1.7.2 Calculation
Sample transport lag time estimated calculations do not consider the volume of
the sample conditioning system. However, the following equation can be used as
a quick method to estimate lag time because normal transport tubing volume is
much greater than sample conditioning system tubing volume.
( Volume [cc ] per Foot of Tubing ) ( Feet of Tubing )
Lag Time =
Actual Sample Flow Rate (cc / min .)
For a detailed method of calculating lag time, see the next section, Calculating
Lag Time.
1.7.3 Analysis Time
If analysis results are used for process control or custody transfer, it is important
to minimize the amount of time that the sample spends in transit from the TCR
sample probe to NGC. To arrive at the total cycle time between representative
samples, sample transit time must be added to NGC cycle time.
1.7.4 Transit Volume
The total volume of sample gas in transit is calculated by multiplying volume per
foot of sample transport tubing by total length of tubing. To assist in making these
calculations, refer to Table 16 for internal volume of commonly used sample
transport tubing.
2101510-002 rev. AE Page 121

Table 16 Internal Volume of Commonly Used Sample Transport Tubing
Tube Outside Diameter

Tube Wall Thickness (in.) Volume per Foot (cc)
(in.)
1/8 0.02 1
1/4 0.035 5
3/8 0.035 15
1/2 0.035 25
1.7.5 Gas Volume in Transit Tubing
Gases are compressible, and the volume of gas in transport tubing for standard
conditions (atmospheric pressure and 70F [21.1C]), is a function of gas pressure
and temperature within tubing.
Ideal gas equation: PV = nRT

Where:
P = Pressure V = Volume
T = Temperature R = Universal Gas Constant
n = Number of moles in sample transport tubing.
n is used to calculate number of moles of gas sample contained in a certain
volume of sample transport tubing.
1.7.6 Mole
Mole is a fundamental unit that describes the number of chemical molecules. One
mole always represents one Avogadros number 6.02x1023 of molecules. Number
of moles can be determined by the calculation formula: n=PV/RT.
Because sample and transport tubing volume and temperature are usually
constant, the number of sample moles in transit is a function of pressure in sample
transport tubing. Reducing gas sample pressure reduces the mass of gas in
sample transport tubing. This is referred to as line peak. Once transport volume
is known for standard conditions, transport lag time can be determined.
1.7.7 Maintaining Phase
When designing sample transport tubing, phase of sample must be maintained.

Gases, containing high concentrations of high boiling components, can cause
problems when they condense on the inside of the transport tubing surface. To
prevent condensation from occurring, heat trace transport tubing uses electrical
power, stream or hot glycol. This prevents components from condensing on
transport tubing walls and prevents any water within the tubing from freezing and
blocking sample flow.
Page 122 2101510-002 rev. AE

1.7.8 Heat Tracing Sample Lines
If there is a possibility that vapor samples could condense in the sample transport
line, heat tracing the sample line should be considered. This could occur at
ambient temperatures or when a liquid has to be kept warm for transporting or to
keep it from freezing (see Figure 116).
To determine heat tracing temperature, a dew point calculation can be
performed, based on the worst case sample composition and transport pressure.
Heat tracing should conform to requirements of national and

local codes.
Figure 116 Heat Tracing Sample Line
1.7.9 Tube Corrosion
When designing transport tubing, the affect that corrosion has on tubing must be
considered. For hydrocarbon service, stainless steel transport tubing, type 316SS,
is recommended.
For selection of transport tubing for different types of service, the user should refer
to reference information applicable to material applications for corrosive
environments.
1.7.10 Tube Preparation
In the course of installing (cutting and fitting) the tubing at an installation, it is

important to dress the ends of any cut tubing and to insure that in the cutting and
deburring process that no particles are allowed to remain in the tubing.
2101510-002 rev. AE Page 123

1.8 Calculating Lag Time
The following calculations assume that all pressure drops occur across the valves
HV-1, HV-2 and HV-6 and that the Rotameters RM-1, RM-2 and RM-3 are
measuring flow at atmospheric pressure (see Figure 117).
Figure 117 is for reference purposes only but, it is typical of a
sample conditioning module with liquid separator and liquid
shutoff. It is included for reference only. Refer to the
documentation provided with the unit.
Figure 117 Typical Sample Installation Diagram
1.8.1 Calculations
Lag time calculation qualifying factors are as follows:

The sample for calculation contains mostly methane gas that flows
through 100 feet of -inch stainless steel tubing with a wall thickness of
0.020-inch. Sample temperature is 80F (26.7C) and pressure is 15 PSIG
(29.7 psia). Bypass rotameter in the sample conditioning system reads
50% of full scale and is calibrated with air to 1180 cc/min at full scale. Air
density is 0.075 lbs/cu. ft.
Page 124 2101510-002 rev. AE

To compute transport tubing lag time, perform the calculation below.
1.8.2 Calculating Using Actual Pressure
Calculating lag time using actual pressure:
VL P + 15 530 1
t = Z
Fs 15 T + 460 p
Where:
T = Purge Time L = Line Length, ft.
V = Tubing Volume, cc/ft. Fs = Standard Flow, cc/min.
P = Actual Pressure, PSIG T = Actual Temperature, F
Zp = Compressibility at P Pressure
In this step, the lowest possible pressure should be used. This
minimizes transport tubing lag time to reduce line or molecule
peak. Care should be taken, to assure that enough pressure is
available, to keep sample flowing throughout the analysis
system.
1.9 NGC8206 Standard Software Features

Totalflows on-board and host software work together to provide many key
features that enable the user to access, control and share data. The user-friendly
interface allows multi-faceted report and communication capabilities without
compromising the integrity of the system or the data.
Modular Software Design-Application Based Plug-In Software Modules.
Audit Quality Historical Data
Operational Alarms
Tri-Level Software Security System
Multiple Calculation Options
Selectable Engineering Units (future)
Analysis Reporting
Communication Protocol Selection
Web Enabled Data Collection
1.9.1 Audit Quality Data
Totalflows software design creates a historically accurate file system that uses
date and time stamped events to create an audit quality data structure.
The unit can collect, analyze and retain (default) stream data for the last 480
analysis cycles, retain the last 35 days of daily stream averages, the last 480
diagnostics reports, the last 480 alarms and last 480 events. Additionally, this can
be reconfigured by the user.
1.9.2 Tri-Level Security
The software security system is designed to have a password administrator who

sets up the accounts and privileges for themselves as well as the other PCCU
users. This privilege includes being able to instantiate applications and make
2101510-002 rev. AE Page 125

changes to the functionality of the NGC. See the Help files in the host software
package for more information.
1.9.3 Compressibility Options
User selectable measurement calculations may be defined individually per stream

and include:
AGA-5
AGA-8 Detail
ISO Summation Factor
Single Virial Summation Factor
None (a factor of one is used)
NX-19
1.9.4 Calculation Options
During Stream Setup, the user may select from several calculation files. Selection
of a suitable file automatically setup other factors such as concentration/Btu basis
and saturated gas treatment (see Table 17). For additional information, please
refer to the PCCU Help files.
Table 17 Calculation File Settings
Calculation File Agency Document Temp1 Temp2 Comp. Constants

gost-30319-aga8 GOST 30319 20 AGA8
gpa-2172-96-aga8-2145-03A-fts GPA 2172-1996 AGA8 2145-03A
iso-6976-1995-15-15 ISO 6976-1995 15 15 ISO Sum Factor
iso-6976-1995-15 ISO 6976-1995 15 None
iso-6976-1995-20-20 ISO 6976-1995 20 20 ISO Sum Factor
iso-6976-1995-20 ISO 6976-1995 20 None
1.9.5 Engineering Units
User selectable engineering units may be defined individually per measurement

stream. These include most metric system units as well as standard US units.
Access to this capability requires instantiation of the unit conversion application
and may be applied to data reporting and visual readings on the VGA screen. For
additional information, please see the host software Help files.
1.9.6 Supported Protocols
The NGC hardware and software support several communication protocols:

Totalflow Local
Totalflow Remote
Modbus Slave (ASCII)
Modbus Slave (RTU)
Modbus Host (ASCII)
Modbus Host (RTU)
Totalflow TCP
Modbus TCP Server
Page 126 2101510-002 rev. AE

Modbus TCP Client
LevelMaster
Supported protocols operate at 1200, 2400, 4800, 9600, 19200, 38400, 57600
and 115200 baud rates.
1.10 PCCU Local Communication Options

Local communication with the NGC requires the use of PCCU32 software running
on a PC and an MMI (man machine interface) cable. Totalflow recommends using
a USB cable for high speed local communication in a remote location. RS-232
serial communication with the NGC can also be a high speed application for users
operating a PC with Windows XP Operating System or newer.
When operating the NGC in a network environment, using Ethernet is an excellent
and practical solution.
For example, the following chart (See Table 18) compares communication times
between the different available options for several common operational tasks:
Table 18 Communication Option Comparison
Operational Task1
Communication Data Coll. Single Stream Save Files Restore Files
Serial: 38,400 Baud 10 Seconds 2.5 Minutes 2.5 Minutes
Serial: 115,200 Baud2 4 Seconds 1.1 Minutes 1.1 Minutes
USB 3 Seconds 1.5 Minutes 1.5 Minutes
Ethernet 3 Seconds 1.5 Minutes 1.5 Minutes
1.11 NGC Start-Up Diagnostics

The Totalflow NGC8206 has an extensive built-in list of tests which are performed
each time the unit is started. This start-up testing may be disabled, but Totalflow
recommends that it be left enabled. These diagnostics consist of four areas of
testing:
Carrier Pressure Regulator Test
Oven Temperature Test
Processor Control Test
Stream Test
These start-up tests may also be performed on a regular schedule. Please see the
PCCU Help files for more information on scheduling diagnostics.
1.11.1 Carrier Pressure Regulator Tests
This test compares the actual column pressure to the column pressure set point
using carrier gas. A failure of this test indicates that the carrier pressure is not
meeting or over exceeding the expected level of pressure.
1 Operational task speed directly correlates to PC Processor speed.
2 Personal Computer operating on Windows XP Operating System or newer.
2101510-002 rev. AE Page 127

1.11.2 Oven Temperature Test
This test compares the actual oven temperature to the oven temperature set point.
A failure of this test indicates that the oven is not maintaining the required
temperature.
1.11.3 Processor Control Test
This test contains three test areas: column 1 carrier pressure, column 2 carrier
pressure and oven temperature. In each area, the test measures the effort
required to maintain the required value. From those measurements, the test
develops a standard deviation and makes a comparison. The failure of any of
these comparisons indicates an erratic deviation exists, meaning the processor is
not able to control the function.
1.11.4 Stream Test
This test measures various pressures for each available stream. Failure of a
stream indicates an inability to meet certain criteria.
During the initial start-up, all streams are disabled. During the stream test, streams
with input pressure are re-enabled, tested and either passed or failed. Streams
with no initial input pressure fail.
1.12 Start-Up Wizard

The NGC8206 Start-up Wizard is designed to walk the technician through
procedures required for setting up the unit. Following installation and connection
to the NGC, the Startup Wizard begins automatically. This only happens the first
time the user connects to the unit or upon start-up each time the user reconnects
to the system until the unit setup is completed.
The wizard is designed to run concurrently with the NGC Diagnostics.
1.12.1 Wizard
The wizard steps through the process of entering information to get the NGC up
and running: device set-up, stream set-up, calibration set-up, etc. Each screen
has an associated Help screen that automatically displays when the user moves
from screen to screen defining what information is required.
1.13 Historical Data

The NGC compiles historical data that can be used for custody transfer needs,
verify NGC operation over time and provide a limited data backup for
communication link reliability. Data retained by the NGC can be collected via a
remote communication link or by a laptop PC operator interface.
1.13.1 Retaining Data
The user can configure how much data is retained by the NGC via the operator
interface. The default configuration is as follows:
1.13.2 Analysis Cycles
The last 480 analysis cycles (default):
Page 128 2101510-002 rev. AE

Normalized Components
Un-Normalized Components
Ideal Btu/CV
Real Btu/CV (Wet(Inferior CV) and Dry (Superior CV))
Relative Density (Specific Gravity)
Density
GPM
Wobble Index [Dry Btu (Superior CV)]
Alarms
1.13.3 Stream Averages

Last 840 hour averages
Last 35 Daily averages
Last monthly average
1.13.4 Diagnostic Reports
The last 480 Analysis Cycles:

Selected Peak Times
Selected Peak Areas
Ideal Btu/CV
Carrier Regulator Pressure
Oven Temperature
Enclosure Temperature
Sample Pressure
Detector Noise Values
Detector Balance Values
1.13.5 Audit Logs

Last 100 alarms
Last 100 events
1.14 TCR Sample Probe (Optional Equipment)

The temperature compensated regulator (TCR) sample probe is used to capture
natural gas from the pipe line for NGC analysis. To capture the gas sample, it is
recommended the TCR sample probe be mounted horizontally. It can be mounted
vertically if this is more suitable to the customers installation.
TCR sample probe is specifically selected for operation with the NGC. The design
of the probe prevents icing without the need for electrical power.
It is the customers responsibility to install and weld a 3/4 inch
female NPT standard pipeline coupling on the main meter run
gas flow pipe. This coupling allows installation of the TCR
sample probe.
Check Table 19 to ensure that the user has the correct sample probe for their
installation. The length of the sample probe is dependent on the diameter of the
customers meter run.
2101510-002 rev. AE Page 129

ABB Totalflow recommends that a TCR be installed with the NGC. Refer to Figure
118.
Please read the installation instructions in Chapter 2 to develop a

pipeline installation plan prior to actual installation.
Table 19 Optional Temperature Compensated Regulator (TCR)
Length
Part Number Description
(inches)
Temperature Compensated Sample Probe
4 1461004-003
/Regulator/Relief Valve
Temperature Compensated Sample Probe
8 1461004-004
/Regulator/Relief Valve
PRESSURE GAUGE RELIEF VALVE
OUTLET PORT 1/4" NPT

CUSTOMER INSTALLED COUPLING
3/4" NPT
SAMPLE PROBE
GAS FLOW
Figure 118 Temperature Compensated Regulator With Sample Probe
1.14.1 Location
Locate the pipeline coupling on the gas meter run, in close proximity to the
NGC. This allows the stainless steel sample line, from sample probe to
Chromatograph, to be as short as possible.
The coupling should be mounted so the probe can be installed horizontally or
vertically on meter run pipe. This means the coupling should be mounted on
either the top or the side of the meter run pipe.
Sample probe should not be mounted at the ends of headers, dead Ts,
large volume accumulators or other spots where gas is likely to be stagnant.
Installation should allow the probe to penetrate the center 1/3 of the main gas
meter run. This allows sufficient heat transfer with the flowing gas sample.
Sample probe inlet should be high enough to avoid sampling of liquids at the
bottom of the pipe.
The sample probe must be installed where probe has access to the fastest
flow of gas within the pipe.
The sample probe should be mounted a minimum of five pipe diameters from
any device which could cause aerosols or significant pressure drops.
Page 130 2101510-002 rev. AE

1.14.2 Other Considerations
TCR sample probe line pressure should be as close to 1-atmosphere as
possible to reduce sample transport lag times due to line pack. Sample
pressure at the NGC should be 15 2 PSIG (103 14 Kpa).
To maintain this pressure at the NGC filters, it may be necessary to increase
TCR sample probe pressure to a value greater than 15 PSIG. Pressure is
dependent on sample transport tubing length between the TCR sample probe
and analyzer.
Be sure to use tubing electrical isolators on sample tubing when connected to
pipelines that are not isolated from cathodic protection.
1.15 VGA Display (Optional Equipment)

The display board provides a panel, VGA monochromatic display to monitor the
process and results. It also provides six magnetic switches to allow a user to
navigate through various screens of data and control the processes (stop
operation, start operation and calibrate).
If the NGC is configured with the front panel display, available screens and user
defined screens may be navigated using the display magnet (Part No. 1801755-
001).
The optional VGA display features:
panel VGA display circuit board.
2 LED Status Indicators, User Programmable (default left LED- flashing light
indicates a fault alarm, and a solid light indicates a warning alarm. Right LED-
solid light indicates unit is NOT in auto run mode.)
User interface, with hall-effect magnet navigation, for monitoring NGC8200
operation.
Figure 119 shows the flow of information accessible through the display.
2101510-002 rev. AE Page 131

C3 1.00000 Dry Btu 1055.03250
IC4 0.29800 Sat. Btu 1037.54830
NC4 0.29900 Rel. Density 0.62388
NEO 3.40000 Compress 0.99763
IC5 0.40000 UnNorm 96.90860
NC5 0.40000
C6+ 0.03000
N2 2.38000
C1 89.69300
CO2 1.00000
C2 5.00000
C3 1.00390 Dry Btu 1055.25650

IC4 0.29863 Sat. Btu 1037.76810
NC4 0.30004 Rel. Density 0.62410
NEO 0.10078 Compress 0.99763
IC5 0.10214 UnNorm 97.16250
NC5 0.10171
C6+ 0.02769
N2 2.37627
C1 89.70186
CO2 0.99191
C2 4.99506
Figure 119 Optional NGC VGA Display Screen
Page 132 2101510-002 rev. AE

1.16 Cold Weather Enclosure (Optional Equipment)
In colder climates (ambient temperatures 0F to -40F) this cold weather
enclosure (CWE) allows mounting of the NGC directly on the pipe. This insulated
weatherproof enclosure has brackets for the NGC, a small start up/calibration
bottle and a removable plug that allows installation of the enclosure over the
probe. This keeps the entire sampling system heated to prevent liquid
condensation of the sample prior to analysis (see Figure 120). Having the
calibration bottle in the heated enclosure ensures a much more stable and
consistent calibration.
1.16.1 Enclosure
The heater and enclosure is designed to maintain a 40F inside temperature when
outside temperature is -40F. The enclosure assembly is 31 x 31 x 31 (inside
dimensions) and is made of polyurethane with hinged cover, access and precut
holes.
1.16.2 Heater Options
Options for this enclosure include a choice of either a 400 watt 120 volt A/C heater
(thermostat present at 50F) or a 1500 Btu/hr. catalytic heater (thermostat preset
at 50F).
1.16.3 Mounting Options
The CWE may be mounted directly on the pipe run, with or without the sample
probe enclosed. Optional support leg(s) are available for added support when
mounted on the pipe run.
Optionally, a free-standing kit may be used to mount the enclosure next to the
meter run.
Figure 120 NGC8200 Cold Weather Enclosure Installation w/ Catalytic Heater
2101510-002 rev. AE Page 133

1.17 Sample Conditioning Modules (Optional Equipment)
For some NGC installations, it may be necessary to install an optional sample
system conditioning module to compensate for non-ideal natural gas samples.
These optional modules are pre-engineered to provide various levels of protection
and bypass flows (see Figure 121). All of the sample conditioning modules
include a level of particulate protection and come in two flow sizes: 50 CC and 450
CC per minute (see Table 110).
For installations where the gas is ideal and the sample probe is located less that
10 from the NGC, no sample conditioning module is required.
1.17.1 Gas Types
The user can select from one of four sample conditioning modules for installations
whose gas samples do not meet the ideal clean and dry conditions. The following
definitions define what is meant by the condition of natural gas to be sampled.
Clean gas is defined as having no particles larger than one micron and no
more than one milligram of solids per cubic meter of gas.
Dry gas is defined as having no more than seven pounds of water per million
cubic feet of gas. Gas has less than 0.1 PPM of liquid at the coldest ambient
condition expected at the coldest point in the system. The liquid can be
water, oil, synthetic lubrication, glycol, condensed sample or any other non
vapor contaminate.
Stable gas is a vapor containing less than 0.1 PPM of liquid when vapor is
cooled to 18.3F (10C) below the coldest ambient temperature possible at
any point in the system.
Figure 121 Available Sample Conditioning Modules
Page 134 2101510-002 rev. AE

Table 110 Sample Conditioning Module Descriptions
Part Number Description

Designed for clean, dry, stable gas, with minor amounts of particulate contamination, where
the sample point is more than 10 (3m) and less than 50 (15m) from the NGC, and the
customer guarantees that upset conditions, compressor failure or other problems never
2102023-001
occur. It is also suitable where a high quality sampling system already exists. NGC bypass
flow is expected to be 10 cc/min. System features:
2 micron filter
Designed for clean, stable gas sample point distances greater than 10 (3m) and less than
50 (15m) and containing minor amounts of liquids such as glycol, compressor oil or water.
2102023-002 This system also handles minor amounts of particulate contamination. System features:
2 micron Filter
Liquid/Vapor Separator
Designed for sample point distances greater than 10 (3m) and less than 150 (50m) with
known particulate and liquid contamination. For stable gas samples containing pipe scale
and other solid contaminates and possibly minor amounts of liquid contamination. System
2102024-001 features:
Particulate/Coalescing Filter
Designed for sample point distance greater than 50 (15m) and less than 150 (50m). The
sample gas is known to contain particulate and liquid contamination with a good probability
of line flooding in upset conditions, enough at times to overflow the coalescer (A+ Avenger)
filter. Also has a Genie membrane for liquid rejection and a Genie liquid shut off to be used
2102494-001 when liquid carry over would harm the chromatograph if it was introduced as a sample. This
model contains a liquid shut off to protect the GC. The liquid shut off resets itself when
liquids are no longer present.
Particulate/Coalescing Filter
1.17.2 Mounting Brackets
Two sample conditioning system mounting brackets are available: a single stream
bracket (see Figure 122) or a multiple stream bracket (Figure 123) for up to
three modules.
See Figure 124 and Figure 125 for installed dimensions.
2101510-002 rev. AE Page 135

Figure 122 Single Stream Sample Conditioning Assembly
Figure 123 Multiple Stream Sample Conditioning Assembly
Page 136 2101510-002 rev. AE

Figure 124 Single Stream Conditioning Module Dimensions
Figure 125 Multiple Stream Conditioning Module Dimensions
2101510-002 rev. AE Page 137

1.18 Security Seal (Optional Equipment)
For some NGC installations, it may be desirable to attach a Security Seal on the
enclosure front and rear End Caps. To accommodate seal, please note the holes
located in the tab located on each End Cap (See Figure 126).
1.18.1 Customer Supplied Materials

1 ea. Security Wire Seal
Seal Press
Figure 126 NGC End Cap Tabs for Security Seal
1.18.2 Instructions
1) Insert security wire through holes located on end cap tabs.
2) Bring ends together and insert through holes in security seal (see Figure 1
27).
3) Use seal press to compress seal into wire. Ensure that wire is firmly
captured inside seal.
Figure 127 Security Wire w/ Seal
Page 138 2101510-002 rev. AE

1.19 Optional Equipment Enclosure (Optional Equipment)
If optional enclosure is used, it may be configured to include other options,
including, but not limited, to a battery pack to provide power to the NGC,
communication equipment, solar power charger and additional I/O.
Three enclosures are commonly used for the NGC installations: the 6200, 6700
and the 6800 optional equipment enclosure.
The 6200 installation will be for AC to DC or DC sites requiring communication
equipment. There is no battery backed option in this installation.
The 6700 enclosure supports AC to DC or DC sites requiring communication
equipment. There is no batter back option in this installation.
The 6800 enclosure supports battery backed3 operation for the NGC via solar
power or a UPS system, AC to DC power or DC to DC power and communication
equipment.
Following local codes for installation, these units would normally be located in a
division 2 or general purpose area. The units may be mounted on a 2 pipe or
mounted on a flat surface, such as a wall.
1.19.1 6200 Optional Equipment Enclosure
The 6200 can accommodate the following equipment:

Communication Kit
110/240 Volt to 12 VDC
110/240 Volt to 24 VDC
The 6700 enclosure can accommodate the following:

Communication Kit
120 VAC / 240 VAC 12 VDC power supply
24 VDC/12 VDC DC to DC converter
Communications shelf for radio/modem
The 6800 enclosure can accommodate the following:

Communication Kit
Solar Panel Power Option (24 VDC Systems Only)
2 ea. 110 AH Batteries
115/230 VAC UPS Power Option (24 VDC Systems Only)
2 ea. 40110 AH Batteries
1.20 Power Supply Options (Optional Equipment)

Power supply options available for the NGC8206 are as follows:
110/240 VAC to 12/24 VDC
115/230 VAC to 12 VDC (explosion proof)
3 Autonomy measured in hours.
2101510-002 rev. AE Page 139

24 VDC to 12 VDC converter
24 VDC solar panel power option
115/230 VAC with UPS to 24 VDC
1.20.1 24 VDC Solar Panel Power Option
The solar panel power option employs a solar controller to maintain voltage on two
110 AH batteries:
14-day autonomy with standard 110 AH batteries without optional heater
5-day autonomy with standard 110 AH batteries with optional heater
Space is provided for communication equipment and fusing for auxiliary
equipment. Auxiliary fusing supports a maximum of two 1 amp loads. The system
disconnects batteries when the voltage drops below the minimum recharge level.
Minimum configuration consists of dual 50W solar panels. System is designed to
accommodate dual 110W solar panels as a maximum.
Auxiliary fusing is not available when using the optional

heater.
Figure 128 6800 Enclosure with 24 VDC Solar Panel Power Supply Option
Page 140 2101510-002 rev. AE

1.20.2 115/230 VAC UPS Power Option (24VDC Systems Only)
This option assumes site availability of 115/230 VAC power. A UPS

(Uninterruptible Power Supply) and two 50 AH batteries provide backup power for
short power interruptions. 100 AH batteries are available for longer autonomy:
3-day autonomy with standard 50 AH batteries and no optional heater
36 hour autonomy with standard 50 AH batteries and optional heater
Space is provided for communication equipment and fusing for auxiliary
equipment. Auxiliary fusing supports a maximum of three 1 amp loads. The
system disconnects batteries when the voltage drops below the minimum
recharge level.
Auxiliary fusing is disabled when on UPS power.
Figure 129 6800 Enclosure with 115/230 VAC UPS Power Option
2101510-002 rev. AE Page 141

1.20.3 Explosion Proof Power Supply (Optional Equipment)
For installations requiring an explosion proof power supply, Totalflow provides two
power supplies (115 VAC and 230 VAC to 12 VDC) that meet these requirements
and are housed in explosion proof enclosures.
1.20.3.1 Enclosure
The custom designed, explosion proof enclosure consists of a square shaped cast
aluminum housing, powder coated, with top explosion proof threaded cap for
access to internal components (see Figure 130).
The top cap has precision engineered threading and is susceptible to damage, if
treated roughly. The top cap is water tight, corrosion resistant and NEMA 4X
rated. Unauthorized removal of the cap is protected with a hex socket set screw
on cap.
Figure 130 Explosion Proof AC Power Supply
Page 142 2101510-002 rev. AE

2.0 INSTALLATION
2.1 Overview
This chapter provides information for field installation of the NGC and optional
equipment. After completing the procedures within this chapter, the NGC is ready
for start-up.
The installation instructions in this chapter are to be performed

only when the area is known to be non-hazardous.
It is highly recommended that the user thoroughly reads this

chapter to establish an installation plan. Also, before
beginning, refer to the wiring diagrams delivered with the new
NGC. Store these under the tab Drawings in the back of this
manual.
2.1.1 What this Means
Installation instructions that feature this icon are applicable

ONLY when the installation involves a cold weather enclosure
(CWE). All other instructions may or may not be applicable.
The following procedures, unless otherwise stated, are
applicable to all NGC units. The NGC is designed to be pipe
mounted (see Figure 21). Optionally, a shelf mounting kit
(see Figure 22) may be purchased for use in mounting the
unit on a wall, inside or outside of a building or a mounting
plate for use in the optional cold weather enclosure (see
Figure 23).
2.1.2 Organization
The following instruction sections are organized in the suggested installation

order. Not all installation instructions will apply to the users situation. For
example, some procedures may vary when the installation does not require
certain equipment.
Please note that where applicable, typical instructions are

first and variations or specialized instructions follow.
2101510-002 rev. AE Page 21

NGC8200
SAMPLE PROBE
CARRIER GAS CALIBRATION GAS
Figure 21 Basic Meter Run Installation
MOUNTING PLATE FLANGE
WALL SHELF
Figure 22 Typical Wall Shelf Mount Installation
Page 22 2101510-002 rev. AE

400 WATT HEATER, 120 VAC OR 230 VAC
Figure 23 Typical Cold Weather Enclosure with Electrical Heater
2.1.3 Locating Area for Installation
The NGC is designed for mounting on main gas lines, 2-inch to 12-inch pipe sizes.
Each type of installation is described within this chapter.
Be certain the installation site is clean and free of foreign debris that could affect
NGC operation.
The NGC should be located as close as possible to the sample probe installation
point. This prevents the need for high gas flow rates through sample lines to
assure the analysis accuracy of the current sample.
If there is more than one stream being analyzed, locate the NGC in a central
location to all sample probe points.
2.1.4 Installation
The following information should help to determine the procedures to follow

depending upon the type of installation: meter run mount, stand alone, shelf mount
located on a building wall or cold weather enclosure (CWE) mounting for
inclement climates.
2.1.5 Pipe Mount
When mounting the unit directly on a meter run, the following installation
procedures may be applicable.
Sample Probe Installation
Pipe Saddle Installation
NGC Installation
Sample conditioning Module Installation
Sample Line Connections
Carrier/Calibration Bottle Rack Installation on Meter Run
2101510-002 rev. AE Page 23

Carrier Gas Regulator with Low Pressure Switch Installation
Calibration Gas Regulator - Low Pressure Switch Installation
Carrier Gas and Calibration Gas Connections
Vent Line Connections
Optional AC/DC explosion proof power supply installation
Optional 115/230 VAC to 12 VDC Explosion Proof Power Supply Installation
Optional equipment enclosure installation
Optional 115/230 VAC UPS Power Supply (24 VDC Systems)
Optional 110/240 to 12/24 VDC power supply installation
Optional 24 VDC to 12 VDC power converter
Optional equipment enclosure battery pack installation
Optional solar panel installation
Optional 24 VDC solar power supply
DC Power Installation
2.1.6 Stand Alone
When mounting the unit on a free-standing pipe, the following installation

procedures may be applicable.
Stand Alone Installation
NGC Installation
Sample Conditioning Module Installation
2.1.7 Wall Shelf
When mounting the unit on a shelf located on a building wall, the following
installation procedures may be applicable.
Shelf Installation
NGC Installation
Page 24 2101510-002 rev. AE

2.1.8 Cold Weather Enclosure
When mounting the unit inside of the cold weather enclosure, the following
installation procedures may be applicable. Please note that the cold weather
enclosure has several mounting options: free standing, meter run and meter run
with support leg(s).
Freestanding Cold Weather Enclosure Installation
Pipe Mounted Cold Weather Enclosure Mounting Kit
Optional Support Leg Kit installation
Cold Weather Enclosure (CWE) Mounting Plate
NGC Installation
Sample Line(s) to NGC inside of Cold Weather Enclosure
CWE Optional Pwr/Comm Outlet Box Assembly
CWE Carrier Gas Bottle Rack Installation
CWE Calibration Gas Bottle Installation
CWE Optional Catalytic Heater Installation
CWE Optional Electric Heater Installation
2101510-002 rev. AE Page 25

The NGC8200 is certified for installation in Classified
Hazardous locations. The heater and fittings in the Cold
Weather Enclosure may not have the same ratings. All
components of the installation, including accessories and
fittings must be approved for the classification rating of the
area of installation.
2.2 Unpacking and Inspection
2.2.1 Shipping Carton
Ensure that there is no external damage to the shipping container. If there is

significant visible external damage, contact the receiving group and report the
damage to the trucking company for a freight damage claim.
2.2.2 Unpacking
The NGC is shipped in specially designed shipping cartons which contains the
unit, mounting brackets, parts list and wiring and interconnect diagrams. Optional
equipment is shipped in a separate carton.
Carefully remove all internal and external packing material. Carefully remove all
items from the box.
2.2.3 Bill of Lading
After removing the protective shipping cover from the NGC, compare shipped
contents with those listed on the Bill of Lading. All items should match those on
Bill of Lading.
2.2.4 Inspection
Examine internal NGC components for evidence of damage.

Points of inspection are:
Visually inspect exterior of unit for dents, chipped paint, scratches, damaged
threads or broken glass plate, etc.
Physically inspect rear interior mounted circuit boards, cables and front
interior mounted circuit boards for loose cables, boards, display and
mounting screws, etc.
If applicable, inspect calibration/carrier gas bottles to be certain they are
correct for the installation.
2.2.5 Damaged Components
If there is any damage, or if there are noticeable defects, notify a local Totalflow
representative. Keep all shipping materials as evidence of damage for carriers
inspection. Totalflow will arrange for immediate repair or replacement.
Telephone: USA: (800) 442-3097 toll free or International: 1-918-338-4880
Page 26 2101510-002 rev. AE

2.3 Sample Probe Installation
If a sample probe has previously been installed, the user may skip these
instructions.
Sample probe pipe coupling should be located on the top of the
meter run but may be mounted vertical or horizontal.
If the sample probe is to be located inside the Cold Weather
Enclosure, it MUST be a vertical mounting on a horizontal pipe
and be installed on the meter run prior to seating the Cold
Weather Enclosure on the meter run.
2.3.1 Materials
NPT pipe coupling (previously installed)
Sample probe (configuration to be determined by the technician based on
installation and local codes.)
Teflon tape
Or Customer Supplied pipe Dope (suitable for chromatography)
2.3.2 Instructions
1) Shut down meter run and isolate from gas source. Be sure to use proper
lockout and tagging procedures.
2) Bleed off gas from meter run.
3) Ensure installed mounting coupling is free from dirt and debris.
4) Ensure sample probe threads are free from dirt and debris.
5) Using Teflon tape or pipe dope, wrap or cover NPT threads of sample probe
(see Figure 24).
6) Insert gas probe into pipeline coupling (see Figure 25).
7) Using the correct tool, tighten probe. Securely tighten so there is no gas
leakage. DO NOT OVER TIGHTEN.
8) Install shut-off valve on secondary side of sample probe if desired.
2101510-002 rev. AE Page 27

PRESSURE RELIEF VALVE
1/4" OUTLET PORT
THREADED NECK 3/4" NPT.
PRESSURE GUAGE
Figure 24 Sample Probe
PRESSURE GAUGE RELIEF VALVE
OUTLET PORT 1/4" NPT

CUSTOMER INSTALLED COUPLING
3/4" NPT
SAMPLE PROBE
GAS FLOW
Figure 25 Sample Probe Insertion
2.4 Stand Alone Installation

If installing an NGC using the pipe saddle mounting kit, use this procedure to
install the pipe saddle. Before beginning, review the procedure and the materials
required for installation.
2.4.1 Material Not Supplied

One 2 pipe with flange
One 2 pipe coupling
or
Page 28 2101510-002 rev. AE

One 2 Mounting pipe (Installed). Length dependant upon final overall NGC
desired height.
Optional equipment may be ordered from Totalflow.
2.4.2 Instructions
1) Select a location to install the mounting pipe that allows easy user access
and is close to the sample probe. Lines should be as short as possible.
2) Install a mounting pipe, being careful to ensure pipe is vertically aligned.
3) Screw 2 pipe coupling onto top of the mounting pipe.
4) Screw optional mounting flange pipe into top of pipe coupling.
Continue to the NGC Installation instructions.
Method of installation must be consistent with customers
company policy.
2.5 Freestanding CWE Installation

If the installation includes a freestanding cold weather
enclosure, follow these instructions; otherwise, skip to the
next section.
2.5.1 Materials
4 ea. -13 x 1 SST Bolt
4 ea. SST Flat Washer
4 ea. SST Split Washer
1 ea. Stand
The following steps typically require two people.
2.5.2 Instructions
1) The stand is made to be symmetrical so that the top and bottom are
identical. Locate the stand base on a flat, stable surface.
2) Set enclosure on top of the stand, oriented as shown in Figure 26.
3) Place a split washer and then a flat washer on one of the 1 bolts and
insert through the bolt hole located in the angle iron into the outermost
corner of the enclosure (see Figure 27).
4) Move channel nut into position so that bolt screws into the nut. Screw the
bolt into the nut, but do not tighten.
5) Repeat for all other corners.
6) Position enclosure on stand, centered front to back, as desired, and tighten
all bolts.
7) Foot plate mounting holes are pre-drilled for mounting to a pad. The
hardware needs to be supplied by the customer.
2101510-002 rev. AE Page 29

Figure 26 Typical CWE Stand Mount Installation
Figure 27 CWE Mounting Hardware
Page 210 2101510-002 rev. AE

2.6 Pipe Mounted CWE Mounting Kit
If the installation includes a pipe mounted cold weather

enclosure, follow these instructions as well as the optional
support leg instructions, if applicable; otherwise, continue to
the next applicable set of instructions.
2.6.1 Materials
2 ea. 2 x 43 Steel Angle Iron
May be used in conjunction with optional support leg kit. See

support leg installation procedures featured in this chapter.
2.6.2 Instructions
1) Set two pieces of angle iron (see Figure 28) on the bottom of the upside
down enclosure. Ensure that the side with the holes is facing the bottom of
the enclosure, and the solid sides of the angle iron are facing each other.
Angle iron should be spaced so that the diameter of the pipe fits in between.
2) Place a split washer and then a flat washer on one of the 1 bolts (see
Figure 29).
3) Insert the bolt through one of the slotted holes, located in the angle iron, into
the outermost corner of the enclosure. Move channel nut into position so
that the bolt screws into the nut.
4) Screw bolt into the nut but leave loose for later adjustment.
5) Install other bolt, split washer and flat washer into the other slotted hole.
6) Repeat for the other angle iron. Final tightening of bolts is done after the
unit is mounted on the pipe to allow for left to right and front to back
positioning.
BOLT HOLES
CHAIN HOLE 43.00
4.12 34.000
.87 (2 1/2)
.87 1.25 STK
CHAIN RETAINER
1.00 ADJUSTMENT
.50
MOUNTING HOLE 1.12 ASSEMBLY HOLE
Figure 28 Mounting Brackets
2101510-002 rev. AE Page 211

(31.00)
Figure 29 Mounting Hardware Installation
7) Remove nut and washers from the adjustment assembly, if necessary (see
Figure 210).
8) Insert the all-thread through the round hole on the adjustment side of the
angle iron.
9) Place the flat washer, split washer and nut on the all-thread.
10) Screw the nut onto the all-thread until the top of the nut is level with the top
of the all-thread. Final tightening may be done after the mounting chain is in
place.
Lift enclosure above meter run allowing enough clearance to

clear pipe and installed sample probe, if applicable.
TIGHTENING CHAIN LENGTHS
.75 FLAT WASHER -001 13.00"

.75 SPLIT WASHER
-002 19.00"
.75 NUT -003 25.00"
MASTERLINK -004 32.00"
.75 ALL THREAD -005 38.00"
Figure 210 Adjustment Assembly
11) Set enclosure on top of the pipe in between the angle iron mounting
brackets. Keep unit steady on top of the pipe.
Page 212 2101510-002 rev. AE

12) Wrap mounting chain underneath pipe (see Figure 211). Feed chain up
through the square retainer hole of the angle iron and pull up until most of
the slack has been taken out of mounting chain.
13) Feed the long flat end of the chain retainer (see Figure 212) through the
middle of a chain link, then move the retainer lock into position where round
peg fits into small round mounting hole.
(31.00)
VIEW A-A VIEW A VIEW B VIEW B-B
Figure 211 Pipe Mount Installation
Figure 212 Chain Retainer Lock
14) Adjust enclosure into final position on the pipe and tighten the nut on the all-
thread (adjustment assembly) until unit is securely in place.
15) If necessary, adjust the enclosure position on the angle iron, and tighten
bolts until secure.
2.7 Optional Support Leg Installation
If the installation includes a pipe mounted cold weather

enclosure and requires an optional support leg or more, follow
these instructions; otherwise, continue to the next applicable
set of instructions.
2.7.1 Materials
1 ea. Pre-Assembled Adjustable Height Support Leg
2101510-002 rev. AE Page 213

Must use with pipe mounting kit.
2.7.2 Instructions
1) Set support leg underneath front or rear (both, if using two kits) of the pipe
mounted enclosure, oriented so that the leg brace is horizontal with the front
of the enclosure (see Figure 213).
2) Place split washer and then the flat washer on one of the 1 bolts.
3) Insert bolt through the hole located in the angle iron into the outermost
corner of the enclosure. Move channel nut into position so that the bolt
screws into the nut.
(31.00)
22.75
TO
37.00
Figure 213 Optional Support Leg Overview
4) Screw the bolt into the nut, but leave loose for later adjustment. Repeat for
the other corner.
5) If installing two support legs, repeat for the other angle iron. Final tightening
of bolts may be done after the support leg(s) are in the desired positioned
on a flat stable surface.
6) Loosen the adjustment handle and drop the leg foot down and retighten the
adjustment handle.
7) Foot plate mounting holes are pre-drilled for mounting to a pad. The
hardware needs to be supplied by the customer.
2.8 Pipe Saddle Installation

If installing an NGC using the pipe saddle mounting kit, use this procedure to
install the pipe saddle. Before beginning, review the procedure and the materials
required for installation. The optional pipe with flange may be used in installations
requiring additional stability.
Page 214 2101510-002 rev. AE

2.8.1 Material Not Supplied
1 ea. pipe Saddle
1 ea. 2 Mounting pipe. Length dependant upon final overall NGC desired
height.
1 ea. 2 pipe with flange (Optional)
1 ea. 2 pipe coupling( Optional)
Optional equipment may be ordered from Totalflow.
2.8.2 Instructions
1) Position pipe saddle on meter run. Select a location that allows easy user
access and is close to the sample probe. Lines should be a short as
possible.
2) Temporarily attach saddle on the meter run pipe using U-bolt and
associated hardware (see Figure 214).
3) Screw one end of the 2 pipe into saddle flange on pipe saddle until wrench
tight. Place level against pipe and vertically align, adjusting saddle until
vertical alignment is achieved.
4) After vertical alignment, securely tighten saddle mounting bolts.
5) If the configuration includes the optional pipe with flange, screw the 2 pipe
coupling onto the top of the mounting pipe.
6) Screw the optional mounting pipe with flange into the top of the pipe
coupling.
Continue to the NGC Installation instructions. Method of
installation must be consistent with customers company policy.
OPTIONAL MOUNTING
FLANGE PIPE
2" PIPE COUPLING
SADDLE
METER RUN
"U" MOUNTING
BOLT
Figure 214 Typical Pipe Saddle Installation
2.9 Shelf Installation

If the installation calls for the NGC shelf mounting kit, use this procedure to mount
the shelf; otherwise, continue to the next applicable instructions. Before beginning,
review the procedure and the materials required for installation.
2101510-002 rev. AE Page 215

2.9.1 Materials
4 ea. x 20 1 SST Hex Head Machine Screws
NGC Mounting Shelf with flange
1 ea. 2 Mounting pipe. Length dependant upon final overall NGC desired
height.
1 ea. 2 pipe with flange (Optional)
1 ea. 2 pipe coupling (Optional)
2.9.2 Instructions
1) Locate wall position where the NGC is to be mounted. The shelf should be
positioned high enough on the wall so all components are accessible to
service personnel. The shelf should be installed in close proximity to the
installed sample probe.
2) Mount the shelf to the wall, being careful to keep level, using four x 20, 1-
inch SST hex head machine screws in each of the four shelf mounting
holes. Refer to Figure 215.
3) Screw one end of the 2 mounting pipe into the flange on the mounting plate
until wrench tight.
4) If the configuration includes the optional pipe with flange, screw the 2 pipe
coupling onto the top of the mounting pipe.
5) Screw the optional mounting pipe with flange into the top of the pipe
coupling.
Continue to the NGC Installation instructions. The method of
installation must be consistent with the customers company
policy.
OPTIONAL MOUNTING
FLANGE PIPE
2" PIPE COUPLING
WALL SHELF
Figure 215 Shelf Installation
Page 216 2101510-002 rev. AE

2.10 Cold Weather Enclosure (CWE) Mounting Plate
If installing an NGC inside a cold weather enclosure, use this
procedure to install the mounting plate inside the enclosure;
otherwise, continue to the next applicable instructions. Before
beginning, review the procedure and the materials required for
installation.
2.10.1 Materials
Mounting plate with flange
2 pipe with flange
4 ea. 5/16 18 UNC X 1 Hex Head Screw
4 ea. 5/16 x .575 x .078 SST Split Washer
4 ea. 5/16 SST Flat Washer
2.10.2 Instructions
1) Place mounting plate (see Figure 216) inside of the cold weather
enclosure, oriented so that each bolt hole is aligned with the mounting
tracks (see Figure 217).
2) Move the channel spring nuts into position underneath slotted mounting
holes.
Figure 216 NGC Mounting Plate
2101510-002 rev. AE Page 217

5/16" CHANNEL SPRING NUTS
MOUNTING TRACK
Figure 217 Cold Weather Enclosure Interior
3) Place the split washer and then the flat washer on one of the 5/16 screws.
Insert the screw through one of the four holes on the mounting base and
into the corresponding channel nut. Do not tighten until the unit is in final
position.
4) Repeat for the other three screw/channel nuts.
5) Screw the 2 pipe into flange on mounting plate until wrench tight.
Continue to the NGC Installation instructions. The method

of installation must be consistent with the customers
company policy.
2.11 NGC Installation

Once the mounting system has been installed, regardless of the type used, these
instructions should be followed to install the NGC onto the mounting pipe.
Before beginning, review the procedure and the materials required for installation.
2.11.1 Materials
Installed Mounting pipe
4 ea. 5/16 hex socket screws (Optional for use with mounting pipe with
flange kit)
NGC
Page 218 2101510-002 rev. AE

2.11.2 Instructions
1) Position the NGC on top of the 2 pipe stand (see Figure 218), in close
approximation to correct orientation.
2) If the installation has the optional mounting pipe with flange, ensure the
screw holes in the upper flange align with the holes located in the NGC
neck bottom (see Figure 219).
For installation inside of a cold weather enclosure, the front display of
the unit would normally face left, with the feed-through assembly facing
the front opening of the enclosure. This allows screen visibility, access
to the feed-through assembly and the termination panel located in the
rear of the housing.
For the shelf mounted units, the unit would be oriented with the feed-
through assembly also facing forward. Sufficient clearance is required
when mounted near an inside corner.
Otherwise, continue to the next step.
3) Secure in place by tightening the hex socket set screw, located in the neck
of the unit, using a 1/8 hex wrench.
OPTIONAL PIPE WALL SHELF

CWE
MOUNTING PIPE SADDLE
MOUNTING
W/FLANGE
PLATE 2" MOUNTING
PIPE
COLD WEATHER
ENCLOSURE MOUNTED
PIPE RUN MOUNTED
WALL SHELF MOUNTING STAND-ALONE PIPE MOUNTED
Figure 218 NGC Mounting
Figure 219 NGC Optional Mounting Flange Pipe
4) If the installation has the optional mounting flange pipe, insert the hex
socket screw through the hole in the welded flange into the neck bottom of
unit and tighten using hex wrench. Repeat for all screws.
2101510-002 rev. AE Page 219

5) If the installation has the optional mounting flange pipe, small adjustments
may be made to orientation. Apply additional pressure to the mounting pipe
with a pipe wrench and then tighten the mounting pipe into shelf mounted
flange or pipe saddle flange.
Otherwise, loosen the hex socket set screw, rotate unit and retighten.
When positioning the unit, the user should take into

consideration the mounting of the sample conditioning
system, conduit locations and access to the rear end cap of
the unit.
2.12 Sample Conditioning Module Installation
2.12.1 Materials
Installed NGC
Single or multiple module mounting kit
1 ea. .312 x 2.5 x 3.62 x 1.5 U-bolt
2 ea. 5/16 SST split washer
2 ea. 5/16 SST flat washer
2 ea. 5/16-18 SST lock nut
Sample conditioning module(s) and hardware
2.12.2 Mounting Kits
Both the sample conditioning module mounting brackets are installed identically.
The single module bracket holds a single stream sample conditioning module,
while the multiple module bracket holds up to three sample conditioning modules.
2.12.3 Instructions
1) On sample conditioning module, align the mounting holes to the
corresponding holes in the bracket. Insert the bolt through the hole in the
bracket, from front to back through the mounting hole in the module (see
Figure 220). Place the split washer and then the flat washer on the bolt.
Screw the nut onto the end of the bolt until finger tight. Repeat for the
second mounting bolt. Tighten both nuts.
2) Repeat for all additional modules.
3) Straddle the mounting pipe with the U-bolt and insert the threaded ends
through the holes located in the bracket so that the bracket back fits flat
against the pipe, and the module mounting lip sets away from the pipe (see
Figure 221).
4) Place the flat washer, then a split washer on the end of the U-bolt. Screw
the nut onto the end of the bolt and finger tighten.
5) Repeat step 4 for the other side of the U-bolt.
6) Move bracket into position underneath the NGC, being careful to allow
clearance for the sample conditioning module(s).
7) Tighten both nuts.
Page 220 2101510-002 rev. AE

Figure 220 Sample Conditioning Module Bracket
VIEW A-A VIEW B-B
A A A A
U-Bolt
B
2" Pipe
SINGLE MODULE BRACKET 2 EA. 5/16-18 SST LOCKING HEX NUT

MULTIPLE MODULE BRACKET
2 EA. 5/16" SST FLAT WASHER
2 EA. 5/16" SST SPLIT LOCK WASHER
Figure 221 Sample System Mounting Kits
2.13 Sample Line Connections

Following the installation of the sample conditioning module(s), the sample tubing
from the sample probe to the sample conditioning system and NGC feed-through
assembly should be installed.
2.13.1 Materials
1/8 SST chromatography grade transport tubing. Length of tubing to be
determined by the technician based on the distance from the sample probe to
the sample conditioning module and the number of sample streams.
2 ea. ferrule and nut (for each sample stream)
1 ea. NPT to 1/8 reducer or other size as determined from the sample
probe output port (for each sample stream)
1 ea. sample conditioning module transport tubing (supplied with sample
conditioning module).
2101510-002 rev. AE Page 221

2.13.2 Instructions
Be certain ends of stainless steel tubing are open and not
restricted.
1) Locate the sample input fitting on the sample conditioning module (see
Figure 222).
2) Locate the sample output fitting on the installed sample probe.
3) Measure and cut the SST tubing to the required length.
4) Make the necessary bends in the tubing to ease installation of the ferrule
and nut into the sample conditioning module input port.
Figure 222 Sample Conditioning Module Installation
If sample conditioning module and NGC are located inside a

CWE, review the following section Sample Line(s) to NGC
inside of Cold Weather Enclosure for information pertaining to
this installation.
Tube, ferrule and nut should always enter connection at a right
angle.
5) If necessary, install the reducer into the sample probe output fitting.
6) Install the ferrule and nut onto one end of the sample tubing.
7) Insert the tubing with the ferrule into the reducer/sample probe output fitting.
Move the nut down onto the ferrule, screw onto fitting and tighten.
8) Install the ferrule and nut onto the other end of the sample tubing.
Page 222 2101510-002 rev. AE

9) Insert the ferrule into the sample conditioning module input fitting. Move the
nut down onto the ferrule, screw onto fitting and tighten.
10) Locate the sample output fitting on the sample conditioning module.
11) Locate the sample input on the NGC feed-through assembly and remove
the sealing screw.
Leave sealing screw in any unused ports. If unused stream
ports are not sealed, moisture can enter the manifold which
can damage the instrument and void warranty.
12) Make the necessary bends in the tubing to ease installation of the tubing
into the output fitting on the sample conditioning module and the ferrule and
Valco nut into the input on the NGC feed-through assembly.
13) Insert the tubing with the ferrule into the output fitting on the sample
conditioning module. Move the nut down onto the ferrule, screw onto fitting
and tighten.
14) Remove the plastic caps from the restrictor coils, the sealing screws from
the feed-through column vents and the sealing screw from the sample vent
lines.
15) Purge the air from the transport tubing by opening the shut-off valve located
on the sample probe.
Be sure to follow requirements of national and local codes

when performing this purge.
16) Insert the tubing with the ferrule into the corresponding input port located on
the NGC feed-through assembly. Move the Valco nut down onto the ferrule,
screw into port and tighten.
17) Repeat for each sample stream.
DO NOT over tighten. After securing tubing, check for gas

leaks.
2.14 Sample Line(s) to NGC Inside of Cold Weather Enclosure
Sample line(s) being installed to a unit located inside the cold

weather enclosure require making minute changes to the
instructions listed for their installation. The following information
and steps should be noted during the installation
2.14.1 Materials
Heat Trace Materials provided by customer for each additional stream
Aerosol Insulating Foam (supplied with enclosure)
2.14.2 Instructions
1) Please follow the heat trace manufacturers suggested installation
instructions for applying heat trace equipment to additional sample streams.
2) Locate the sample boot on the side of the cold weather enclosure (see
Figure 223).
2101510-002 rev. AE Page 223

Figure 223 Sample Boot
3) Using instructions covered previously under Sample Line Connections, run

the sample line from the sample probe through the sample boot to the
sample conditioning module located below the NGC.
4) Repeat for each additional sample stream.
5) When the sample line connections are complete, apply aerosol insulating
foam from inside the enclosure pointing toward the outside of boot, ensuring
that the overspray falls outside the enclosure.
2.15 CWE Optional Pwr/Comm Outlet Box Assembly

If installing the NGC inside a cold weather enclosure, use this
procedure to install the optional RS-232/RS-485/RS-422 outlet
box, if required; otherwise, continue to the next applicable
instructions. Before beginning, review the procedure and the
materials required for installation.
2.15.1 Materials
1 ea. outlet box assembly
1 ea. internal NGC connection assembly
1 ea. flexible cable assembly
1 ea. DC power switch box
1 ea. support bracket
2 ea. 10-32 x SS pan head screw, phillips
2 ea. #10 SST flat washer
2 ea. #20 SST split washer
Materials for external wiring (to outlet box) not provided by Totalflow.
Quantities and materials to be determined by the technician based on
installation and local codes.
Page 224 2101510-002 rev. AE

2.15.2 Instructions
1) Remove the left side access plate, if so equipped, from the enclosure (see
Figure 224).
2) Gain access to the rear termination panel of the NGC by loosening the
countersunk hex socket locking set screw in the rear end cap using a 1/16
Hex wrench and then unscrewing the end cap.
3) Remove the hub plug from the bottom most access hub.
4) Beginning with the internal connection assembly (see Figure 225), feed the
13 wire bundle (elbow end of assembly) through the open hub. Continue to
pull wire past terminations until the nipple fitting is in position to screw into
the hub.
5) Moving the assembly clockwise, screw the nipple fitting into the hub until the
assembly is tight and hanging straight down.
6) Feed the other end of the wire bundle through the flexible cable assembly,
beginning at the end with the sealing gasket, until threads meet the conduit
seal.
7) Rotate the flexible cable assembly clockwise, screwing threads into the
conduit seal until tight. For explosion proof installation, a minimum of five
threads engaged are required.
8) Feed the wires through the small hole located near the sample boot in the
lower front of the CWE.
INTERNAL
CONNECTION ASSY
ACCESS OPENING
FLEXABLE CABLE
OUTLET BOX ASSY
DC POWER SWITCH
Figure 224 CWE Access Panel Removed
2101510-002 rev. AE Page 225

DC POWER SWITCH INTERNAL NGC CONNECTION ASSEMBLY
OUTLET BOX ASSEMBLY FLEXIBLE CABLE ASSEMBLY
Figure 225 Power Communications Outlet Box Assembly
9) Remove the cover from the outlet box assembly.
Remove the elbow cap on the outlet box assembly to facilitate

feeding the wrapped wire around the elbow.
10) Feed wires through the outlet box elbow and out past the wiring panel,
moving assembly up to the threaded end of the cable.
11) Begin threading the outlet box assembly onto the end of the flexible cable
assembly, rotating the entire outlet box assembly clockwise until tight and in
a vertical position. For explosion proof installation, a minimum of five
threads engaged are required.
12) Locate the support bracket mounting holes on enclosure.
13) Place the split washer, then a flat washer on the end of each screw.
14) Insert the screw through the mounting bracket and into the hole on the side
of the enclosure.
15) Using a Phillips point screwdriver, start the screw into the hole, but do not
tighten.
16) Repeat Steps 13 through 15 for the second screw.
17) Level the bracket and then tighten screws until snug.
18) Move the outlet box assembly down so that it rests on the mounting bracket
(see Figure 226).
19) At the NGC termination panel, trim and strip wire ends.
20) Remove the power field termination J1 connector from the termination
panel.
Page 226 2101510-002 rev. AE

INSULATED ENCLSOSURE WALL
DC POWER SWITCH FLEXABLE CABLE ASSEMBLY
NGC8200
MOUNTING BRACKET
CONDUIT SEAL-TO BE COMPLETED BY CUSTOMER
OUTLET BOX ASSEMBLY
Figure 226 Assembled Power/Communication Assembly
21) Using the wiring instructions in Figure 227, install each wire into the correct
terminal and replace the connector on board.
22) Trim and strip the wire ends located in the external outlet box.
23) Remove the power field termination J3 connector from the outlet box panel.
24) Using the wiring instructions in Figure 227, install each wire into the correct
terminal and replace the connector on board.
25) Remove the DC power switch box cover.
J1
(+) (-)
D1
POWER
Figure 227 Power Wiring Diagram
2101510-002 rev. AE Page 227

26) Remove the switch mounting screws and remove the switch.
27) Cut a 3 length of power (+) wire.
Optionally, the communication wires may be run directly to the

spare conduit hub, located on the bottom of the outlet box
assembly. Follow the requirements of the national and local
codes.
For the purpose of this manual, it is assumed that the
communication wiring is included with the power wiring in one
conduit run.
28) Tape the 3 power (+) wire, ground and communication wire ends together.
29) Feed-through the conduit hub located on the bottom of the DC power switch
box, past the cover opening, around the elbow and out.
30) Continue pulling wire until approximately 2 of the wire is extending out of
the DC power switch.
Be careful to not pull the 3 power (+) wire past the DC power
switch box opening.
31) Feed excess wire through the 6 nipple fitting, conduit seal, 5 nipple fitting
and out into the outlet box opening. Pull sufficient wire to complete the field
wiring.
32) Remove the power field termination J4 connector from the outlet box panel.
33) Using the wiring instructions in Figure 227, install the power (+) and power
(-) wires into the correct terminal pins and replace the connector on the
board.
34) Holding the wires, slide the DC power switch box up to the 6 nipple fitting
on the end out outlet box assembly.
35) Slide the conduit union onto the end of the nipple fitting and screw on.
36) Loosen the terminal screws on the DC power switch.
37) Using the wiring instructions in Figure 227, wire the power (+) to the upper
terminal screw and tighten.
38) Bring the new power (+) wire into the power switch enclosure and pull the
short length out to allow for wiring.
39) Using the wiring instructions in Figure 227, wire the new power (+) length
to the bottom terminal screw and tighten.
40) Using the wiring instructions in Figure 227, wire the new power (+) length
to the bottom terminal screw and tighten.
41) Using the wiring instructions in Figure 228 (RS-232), Figure 229 (RS-485)
or Figure 230(RS-422), make field connections to plug the NGC
termination panel com port(s) and re-insert into the corresponding
connector in the termination panel.
42) Using the wiring instructions Figure 228 (RS-232), Figure 229 (RS-485)
or Figure 230(RS-422), make the field connections to plug J1 and re-insert
into the corresponding connector in the outlet box.
Page 228 2101510-002 rev. AE

43) Using the wiring instructions in Figure 228 (RS-232), Figure 229 (RS-485)
or Figure 230(RS-422), make the field connections to plug J2 and re-insert
into the corresponding connector in the outlet box.
Communication wiring terminations inside the
power/communication outlet box assembly are pass-through
connections, meaning that J1-pin 1 is associated with J2-pin 1.
As such, pin outs may be user defined and wiring instructions
for this assembly are only suggestions.
External wiring and connections should be performed by
person(s) qualified for the type and area of installation,
according to national and local codes.
44) Following instructions included with the unit, complete the seal between DC
power switch and the outlet box assembly.
NGC 8200
TERMINATION BOARD
2102080-XXX
J9 J11
1 2 3 1 2 3
GND 1 1
1
COMM 1
SW PWR 2 2 1
2 2
RTS 3 3
3 3
TXD 4 4
4 4
RXD 5 5
5 5
CTS 6 6
6 6
GND 7 7
7 7
SW PWR 8 8
8 8
9 9
COMM 2
RTS
9 9
TXD 10 10
J8 COMM PORT 1 J10 COMM PORT 2
RXD 11 11
CTS 12 12
Figure 228 Suggested RS-232 Wiring Instructions
2101510-002 rev. AE Page 229

NGC 8200
TERMINATION BOARD
2102080-XXX
1 2 3 1 2 3
J9 J11
GND 1 1
1 1
COMM 1
SW PWR 2 2
2 2
RRTS 3 3
3 3
BUS+ 4 4
4 4
BUS- 5 5
5 5
6 6
6 6
GND 7 7
7 7
SW PWR 8 8
8 8
9 9
COMM 2
RRTS
9 9
BUS+ 10 10
BUS- 11 11
12 12
NGC 8200
TERMINATION BOARD
2102080-XXX
1 2 3 1 2 3
J9 J11
GND 1 1
1
COMM 1
SW PWR 2 2 1
2 2
TXD+ 3 3
3 3
TXD - 4 4
4 4
RXD+ 5 5
5 5
RXD- 6 6
6 6
GND 7 7
7 7
SW PWR 8 8
8 8
9 9
COMM 2
TXD+
9 9
TXD - 10 10
RXD+ 11 11
RXD- 12 12
Page 230 2101510-002 rev. AE

2.16 Carrier/Calibration Bottle Rack Installation on Meter Run
The carrier/calibration gas bottle rack is used to hold the carrier and calibration
gas bottles on installations not using a cold weather enclosure. A gas regulator
should be installed on each gas bottle (see Figure 231). This bottle rack is not
available through Totalflow; therefore, the instructions are generalized.
2.16.1 Instructions
1) Position the bottle rack in close proximity to the NGC.
2) Secure the rack to the pipe meter run with the provided mounting hardware.
3) Install both the carrier and calibration gas bottles in the rack.
4) Strap both bottles in the rack to prevent their falling.
CARRIER CALIBRATION
GAS GAS
TO NGC
Figure 231 Carrier/Calibration Gas Bottle Rack Installation
2.17 CWE Carrier Gas Bottle Rack Installation

The carrier gas bottle rack is used to hold carrier gas bottles
and is installed on the back of the cold weather enclosure (see
Figure 232). A gas regulator should be installed on each gas
bottle.
2.17.1 Materials
1 ea. bracket with chain assembly attached
2 ea. 3/8-16 x 5/8 SST hex head bolt
2 ea. 3/8 SST split washers
2 ea. 3/8 SST flat washers
2101510-002 rev. AE Page 231

2.17.2 Instructions
1) Place a split washer and then a flat washer on one of the 5/8 bolts. Insert
the combination through the bolt hole located in the bottle rack bracket and
into the corresponding hole located along the bottom edge of the enclosure
and tighten (see Figure 233).
Enclosure hole contains a captive nut.
2) Repeat for the second bolt.

3) Install the carrier gas bottle in the bottle rack.
4) Using chains, strap the bottle(s) to the rack by attaching the bolt snap to
one of the center chains.
5) Repeat step 4, if installing a second bottle.
Figure 232 Dual Bottle Rack Assembly
Page 232 2101510-002 rev. AE

Figure 233 Dual Bottle Rack Installation
2.18 Carrier Gas Regulator with Low Pressure Switch Installation

The following instructions are valid for all installations.
2.18.1 Materials
Carrier regulator assembly with low pressure switch (see Figure 234)
Installed carrier gas bottle
These instructions assume that the carrier gas bottle has

previously been installed.
2.18.2 Instructions
1) Remove protective cap from the high pressure inlet, if required.
2) Insert the ferrule on the regulator high pressure inlet into the calibration gas
bottle outlet.
3) Screw the nut onto the thread and tighten.
DO NOT connect the low pressure switch directly to the NGC

without a barrier.
4) Remove the J2 field wiring connector from the NGC termination panel
located inside the rear of the enclosure (see Figure 235).
2101510-002 rev. AE Page 233

LOW PRESSURE SWITCH
CABLE TO BARRIER
HIGH PRESSURE PORTS
INCREASE
LOW PRESSURE PORTS
DECREASE
HIGH PRESSURE INLET
MEDIUM PRESSURE PORT
Figure 234 Carrier Gas Pressure Regulator with Relief Valve
BARRIER REQUIRED FOR ALL

INSTALLATIONS OTHER THAN
NON-HAZARDOUS
(+) (-) (+) (-) (+) (-)(+) (-)

J2 1 2 1 2
INPUTS OUTPUTS REGULATOR CARRIER
DIGITAL I/0 ASSY CYLINDER
NGC TERMINATION BOARD
Figure 235 Carrier Gas Low Pressure Switch Wiring Instruction
5) Using a small flat blade screw driver, loosen DI2 pins 3 and 4.
6) Insert the red wire into the (+) terminal (pin 3).
7) Retighten pin 3.
8) Insert the black wire into the (-) terminal (pin 4).
9) Retighten pin 4.
10) Replace the termination connector in the J2 board connector.
Page 234 2101510-002 rev. AE

2.19 CWE Calibration Gas Bottle Installation
The Calibration Gas Bottle mounting Rack is used to hold the

Calibration Gas Bottle when located inside of the Cold
Weather Enclosure. A gas regulator should be installed on
each gas bottle. Refer to Figure 236.
2.19.1 Materials
Strapping material (shipped with CWE)
Calibration gas blend bottle
2.19.2 Instructions
1) Locate the bottle bracket in the right front area of the Cold Weather
Enclosure (see Figure 236).
2) Set Calibration bottle inside of enclosure, situated against the Bottle
Bracket.
3) Thread strap through holes in bracket and around the bottle. Insert end of
strap into Worm Gear.
4) Using a flat blade screw driver, turn screw on Worm Gear until strap is
snug.
NGC8200
CAL BLEND REGULATOR ASSY
CAL BLEND CYLINDER
WORM GEAR CLAMP
RIGHT SIDE CUT-AWAY VIEW
Figure 236 Calibration Bottle Location
2101510-002 rev. AE Page 235

2.20 Calibration Gas Regulator - Low Pressure Switch Installation
The following instructions are valid for all installations.
2.20.1 Materials
Calibration blend regulator assembly with low pressure switch (see Figure 2
37)
Installed calibration gas bottle
These instructions assume that the Carrier gas bottle has

previously been installed.
2.20.2 Instructions
1) Remove protective cap from high pressure inlet if required.
2) Insert ferrule on regulator high pressure Inlet into calibration gas bottle
outlet.
3) Screw nut onto thread and tighten.
DO NOT connect low pressure switch directly to the NGC

without a Barrier.
4) Remove J2 field wiring connector from NGC termination panel located

inside the rear of the enclosure (see Figure 238).
Figure 237 Calibration Gas Pressure Regulator with Relief Valve
Page 236 2101510-002 rev. AE

BARRIER REQUIRED FOR ALL
INSTALLATIONS OTHER THAN
NON-HAZARDOUS
(+) (-) (+) (-) (+) (-)(+) (-)

J2 1 2 1 2 CAL
INPUTS OUTPUTS REGULATOR BLEND
DIGITAL I/0 ASSY CYLINDER
NGC TERMINATION BOARD
Figure 238 Calibration Blend Low Pressure Switch Wiring Instruction
5) Using a small flat blade screw driver, loosen DI2 pins 3 and 4.
6) Insert the red wire into the (+) terminal (pin 3).
7) Retighten pin 3.
8) Insert the black wire into the (-) terminal (pin 4).
9) Retighten pin 4.
10) Replace the termination connector in J2 board connector.
2.21 Carrier Gas and Calibration Gas Connections

The following procedures describe the steps for connecting the external carrier
gas and calibration gas lines from the respective regulators to the feed-through
assembly on the NGC. They are applicable for both a meter run and a cold
weather enclosure installation.
2.21.1 Materials
Installed carrier gas pressure regulator
1/16 SST chromatography grade transport tubing (Amount to be determined
by the technician based on the distance from carrier gas bottle regulator to
the sample input filter).
Installed calibration gas pressure regulator
1/16 SST chromatography grade transport tubing (Amount to be determined
by the technician based on the distance from the calibration gas bottle
regulator to the sample input filter).
4 ea. 1/16 ferrule and nut
2 ea. NPT to 1/16 reducer or other size as determined from the
carrier/calibration gas regulator.
These instructions assume that the regulators and gas bottles

have previously been installed.
2101510-002 rev. AE Page 237

2.21.2 Instructions
1) Locate the carrier gas input port (CAR) on the NGC feed-through assembly
(see Figure 239).
2) Locate the low pressure output fitting on the installed pressure regulator.
3) Measure and cut the 1/16 SST tubing to the required length.
4) Make the necessary bends in the tubing to ease the installation of the tubing
into the NGC and pressure regulator.
Figure 239 Carrier and Calibration Gas Connections
Tube, ferrule and nut should always enter the connection at a

right angle.
5) Install the reducer into the carrier gas regulator.

6) Insert the tube with the ferrule into the reducer/pressure regulator output
fitting. Move the nut down onto the ferrule, screw onto fitting and tighten.
7) Carrier gas pressure should be set at 90 PSIG.
8) Locate the carrier gas input (CAR) on the NGC feed-through assembly and
remove the sealing screw.
Leave sealing screw in any unused ports. If unused stream
ports are not sealed, moisture can enter the manifold which
can damage the instrument and void warranty.
on the regulator.
Be sure to follow the requirements of the national and local

codes when performing this purge.
10) Insert the tube with the ferrule into the carrier gas input port (CAR) on the
feed-through assembly. Move the Valco nut down onto the ferrule, screw
into port and tighten.
Page 238 2101510-002 rev. AE

11) Determine the input port for the calibration gas (typically S4) on the NGC
feed-through assembly (see Figure 2-43) and remove the sealing screw.
12) Locate the low pressure output fitting on the installed pressure regulator
on the calibration gas bottle.
13) Measure and cut the 1/16 SST tubing to the required length.
14) Make the necessary bends in the tubing to ease the installation of the
ferrule and tubing into the NGC and pressure regulator.
Tube, ferrule and nut should always enter connection at a

right angle.
15) Install the reducer into the calibration gas regulator, if required.
16) Insert the tube with the ferrule into the reducer/pressure regulator output
fitting. Move the nut down onto the ferrule, screw onto fitting and tighten.
17) Calibration gas pressure should be set at 15 PSIG.
on the regulator.
Be sure to follow the requirements of national and local codes

when performing this purge.
19) Insert the tube with the ferrule into the calibration gas input port (S4) on the
feed-through assembly. Move the Valco nut down onto the ferrule, screw
into port and tighten.
Leak test ALL gas connections when completed.
2.22 Vent Lines Connections

The following procedure provides general steps for connecting the external vent
lines from the respective output ports on the feed-through assembly. When the
NGC is installed in a CWE, the sample vent line MUST vent outside of the CWE.
Other installations may only require short lines. Please follow the requirements of
national and local codes during this installation.
2.22.1 Materials
4 ea. 1/16 ferrule and nut
4 ea. 1/16 SST vent tubing (supplied with NGC) or
4 ea. 1/16 SST tubing (Amount to be determined by the technician based on
the distance from the NGC to the external vent location).
2.22.2 Instructions
1) Locate the gauge port vent (GPV), sample vent (SV)), column vent 1 (CV1)
and column vent 2 (CV2) ports on the NGC feed-through assembly (see
Figure 240). Remove the sealing screws for the vent ports.
2101510-002 rev. AE Page 239

2) Using the supplied vent tubing (if sufficient length) and ferrule, place the nut
and ferrule onto the short end of the bent tubing. Insert the tubing and
ferrule into one of the vent ports, with the open end of the tubing pointing
down. Move the Valco nut down onto the ferrule, screw into the port and
tighten.
If vent tubing is not of sufficient length, measure and cut new tubing (not
supplied by Totalflow). Make the necessary bends to install the tubing.
Place the nut and ferrule onto the corresponding end of the tubing. Insert
the tubing and ferrule into one of the vent ports, being careful to keep tubing
horizontal, with the open end of the tubing pointing down. Move Valco nut
down onto the ferrule, screw into port and tighten.
3) Repeat step 2 for ALL other vents as listed in step 1.
All four vents MUST be open to atmospheric pressure without
back pressure. Position the vent tubing in a downward
direction so that moisture does not accumulate in the tubing.
Figure 240 Vent Line Connections on Feed-through Assembly
2.23 CWE Optional Catalytic Heater Installation
The following procedures describe the steps for installing a

catalytic heater for the cold weather enclosure.
Verify the heater and fittings are approved for the classification
rating of the area of installation.
Page 240 2101510-002 rev. AE

2.23.1 Materials
Catalytic heater (installed at factory)
Thermostat assembly with temperature probe
Regulator assembly w/ shut-off
T assembly
Tubing
Temperature probe mounting clip
Teflon tape
Male pipe connection from external gas source to catalytic heater.
Materials for the gas source are not provided by Totalflow. Quantities and
materials to be determined by the technician based on installation and local
codes.
DC power source wiring. Materials for external power source for electrical
preheat wiring are not provided by Totalflow. Quantities and materials to be
determined by the technician based on installation and local codes.
2.23.2 Instructions
1) Locate the installed catalytic heater on the rear of the cold weather
enclosure (see Figure 241).
2) Remove the protective end cap from the catalytic heater input fitting, if
required.
3) Apply Teflon tape to the threads on the male end of the T assembly (see
Figure 242).
4) Screw the threaded end of the T assembly into the female fitting, located
on the factory installed catalytic heater, by turning the entire assembly
clockwise until tight (see Figure 243).
5) Remove the ferrules and nut from the male connector on the bottom of the
T assembly.
6) From inside the CWE, insert the short bent end of the 3/8 tubing out
through the hole located below the catalytic heater, and continue feeding
the tubing out until it is in position to insert into the bottom of the T
assembly.
Figure 241 Catalytic Heater Option in Cold Weather Enclosure
2101510-002 rev. AE Page 241

THERMOSTAT
REGULATOR
TEMPERATURE PROBE SERVICE COCK
1/4 NPT PLUG
MALE, 1/4 NPT

3/8" TUBBING
MALE, 3/8 x 1/4 NPT
MALE CONNECTOR,
3/8 x 1/4 NPT W/ REGULATOR
FERRULES AND NUT
T ASSEMBLY TUBING THERMOSTAT ASSEMBLY REGULATOR ASSEMBLY
Figure 242 Catalytic Heater Assembly
Figure 243 Thermostat Assembly Installed
7) Place the nut, front ferrule and back ferrule onto the outside end of the
tubing and position so that the ferrules and nut screw onto the bottom of the
T assembly. Screw nut until tight.
8) Remove ferrules and nut from the thermostat end of the thermostat
assembly.
9) From inside CWE, insert the tube end of the thermostat assembly through
the exterior wall on the side of the CWE (see Figure 244).
10) Place the nut, front ferrule and back ferrule onto the end of the 3/8 bent
tubing (from the T assembly beneath the catalytic heater) inside of the
CWE. Position the thermostat assembly so that the nut and ferrules screw
onto the thermostat assembly.
11) Remove the ferrules and nut from the end of the regulator assembly closest
to the service cock.
12) Place the nut, front ferrule and back ferrule onto the end of the thermostat
assembly protruding from the CWE.
13) Hold the regulator assembly with the curved tubing on top, above the
protruding tubing. Insert the tubing into the regulator assembly, slide the
ferrules and nut into place and tighten.
Page 242 2101510-002 rev. AE

Figure 244 Regulator Assembly Installed
14) Gently uncoil the temperature probe capillary tubing from the thermostat
and insert through the hole located below the thermostatic gas valve, being
careful to not crimp or make sharp bends in the capillary tubing.
15) Remove the mounting screw and washers from the right rear NGC
mounting bracket (see Figure 245).
16) Insert the screw with washers still in place through the hole located on the
mounting clip, and re-insert through the mounting bracket into the channel
nut..
17) Position the probe underneath the mounting clip. Tighten the screw into the
channel nut to hold the probe in place.
The technician responsible for installing the gas supply must

be qualified for the type and area of installation according to
national and local codes.
Figure 245 Temperature Probe Installation
2101510-002 rev. AE Page 243

18) Using the regulator manufacturers instructions supplied with the regulator,
make the external gas connections.
The installation must be performed by person(s) qualified for
the type and area of installation according to national and
local codes.
19) Using the wiring instructions shown in Figure 246 and the manufacturers
instructions enclosed with the heater, make external connections.
ELECTRICAL PREHEAT CONDUIT BOX
12 VDC POWER SOURCE
POSITIVE
NEGATIVE
Figure 246 Electrical Pre-Heater Wiring Instructions
2.24 CWE Optional Electric Heater Installation
The following procedures describe the steps for wiring an

electric heater for the cold weather enclosure.
Verify the heater and fittings are approved for the

classification rating of the area of installation.
2.24.1 Materials
Electric heater Option (Factory Installed, see Figure 247)
AC Power source wiring. Materials for external Power source for Electric
heater wiring not provided by Totalflow.
Quantities and materials to be determined by the technician
based on installation and local codes.
Installation must be performed by person(s) qualified for the
type and area of installation according to National and Local
codes.
Page 244 2101510-002 rev. AE

2.24.2 Instructions
1) Using the wiring instructions shown in Figure 248 and the manufacturers
instructions enclosed with the heater, make external connections.
400 WATT HEATER, 120 VAC OR 230 VAC
Figure 247 Electrical Heater Installed in CWE
Figure 248 Electric Heater Option Wiring Instructions
2101510-002 rev. AE Page 245

2.25 Optional Equipment Enclosure Installation
If the optional enclosure is used, it may be configured to include other options,
including, but not limited to, a battery pack to provide reserve power to the NGC,
communication equipment, solar power charger and additional I/O.
Three enclosures are commonly used for the NGC8201 installations: the 6200,
6700 and 6800 enclosure. The unit may be mounted on a 2 pipe or mounted on a
flat surface such as a wall
If configured, the battery and solar panel are packed and shipped separately from
the Optional Equipment Enclosure.
Before beginning, review the procedures and the materials required for the
installation; inspect all power cables where they terminate and the connector for
breakage.
The Optional Equipment Enclosure may be approved for
classified hazardous locations or potentially explosive
atmospheres. Verify the rating listed on the unit tag and install
per the referenced control drawing. Be sure to follow the
requirements of national and local codes when installing the
Optional Equipment Enclosure.
The 6200 can accommodate the following equipment:

Power Supply Kit for 6200
120 VAC/12 VDC Power Supply
The 6200 installation will be for AC and 24 VDC sites. There is no battery backed
option in this installation.
The 6700 Optional Equipment Enclosure can accommodate the following:

Power Supply Kit
24 VDC/12 VDC DC to DC converter 2015440-005)
Solar Panel Charger
XFC/XRC Electronic Board
XFC/XRC Onboard Battery Charger will be used
Battery Options
1 each 26/30 AH Battery
Communications Shelf for Radio/Modem
The 6700 enclosure supports battery backed operation for the NGC. The
XFC/XRC electronic board provides a battery charger/regulator for the system.
2.25.3 6800 Enclosure
The 6800 enclosure can accommodate the following :

Solar Panel Power Option (24 VDC Systems Only)
Page 246 2101510-002 rev. AE

115/230 VAC UPS Power Option (24 VDC Systems Only)
2.25.4 Location
Mount the enclosure on a nearby wall, panel or pole. Make sure that the approved
conduit can be installed between the power supplys enclosure and the NGC.
Avoid obstructions.
2.25.5 Pipe Mount Instructions
Enclosure mounting brackets and fastening hardware are supplied with unit.
Customer must provide 2 pipe of suitable length (see Figure 249).
If a charging source, such as a solar panel is desired, this procedure may be
adapted to mount the solar panel on the upper portion of the pipe.
Instructions assume the mounting pipe has been previously installed. If not, refer
to installation sections previously in this chapter for either free standing pipe
installation or pipe saddle installation.
1) When the unit is received, unpack and inspect all components for evidence
of damage. Report damage to the shipping carrier and to Totalflows service
department.
2) Using instructions supplied with the mounting kit, attach the bracket to the
back of enclosure unit.
3) Position the unit on the 2 mounting pipe and secure in place with two U-
bolts, split washers, flat washers and two bolts (see Figure 249, Figure 2
50 and Figure 251).
Figure 249 6200 Enclosure Pipe Mounting Installation
2101510-002 rev. AE Page 247

2.00 PIPE
(2.38 O.D.)
Page 248 2101510-002 rev. AE

2.25.6 Wall Mount
A typical installation should be similar to Figure 252, Figure 253 and Figure 2
54.
Enclosure mounting brackets and fastening hardware are supplied with the unit.
2.25.6.1 Wall Mount Instructions

of damage. Report damage to the shipping carrier and to ABB Totalflows
service department.
back of the enclosure unit.
3) Prepare the wall surface for mounting, and mount the enclosure to the wall.
MOUNTING BRACKET
Figure 252 6200 Enclosure Wall Mounted Installation
2101510-002 rev. AE Page 249

MOUNTING BRACKET
(15.83") (.60")
MOUNTING
BRACKET
(31.20")
(30.00)
FLAT AND LOCK WASHER

WITH SCREW
Page 250 2101510-002 rev. AE

2.25.6.2 Wall Mount Instructions
of damage. Report damage to the shipping carrier and to Totalflows service
department.
back of the enclosure unit.
3) Prepare the wall surface for mounting, and mount the enclosure to the wall.
2.26 115/230 VAC UPS Power Supply (24 VDC Systems)

This power supply may be approved for classified hazardous
locations or potentially explosive atmospheres. Verify the
rating listed on the unit tag, and install per the referenced
control drawing. Be sure to follow the requirements of national
and local codes when installing the power supply.
type and area of installation, according to national and local
codes.
2.26.1 Instructions
1) If configured, the optional equipment unit should contain an installed power
supply. The optional equipment enclosure should be installed using
instructions shown previously in this chapter.
2) Remove the necessary plugs from the side of the enclosure to install the
rigid conduit.
3) Pipe the conduit and associated AC wiring into the enclosure.
Please review the Grounding the NGC section in Chapter 1-

System Description before making power connections.
4) Using wiring instructions in Figure 255, make the field connections from
the 115 VAC hot and neutral or the two hot wires for 230 VAC as shown in
the wiring instructions.
5) Pipe the conduit and associated DC wiring from the NGC into the power
supply enclosure. See Table 14 in Chapter 1 for wire sizes.
6) Remove the J1 connector from the NGC termination panel. Using the wiring
instructions in Figure 255, make field connections from the power supply
wire as shown to J1 connector (+) pin and connect the ground wire to J1
connector (-) pin. DO NOT re-insert the J1 connector to the termination
board.
7) Proceed to the battery pack installation instructions later in this chapter.
8) Go to DC power installation later in this chapter.
2101510-002 rev. AE Page 251

10Amp
TB5, Spare 1Amp
5Amp
TB4, Spare 1Amp
TB3, Spare 1Amp
TB2, NGC
TB1, Batt
Figure 255 115/230 VAC UPS Power Supply Option
2.27 115/230 VAC to 12 VDC Explosion Proof Power Supply Installation

The AC/DC power supply may be approved for classified
hazardous locations or potentially explosive atmospheres.
Verify the rating listed on the unit tag and install per the
referenced control drawing. Be sure to follow the requirements
of national and local codes when installing the power supply.

codes.
2.27.1 Customer Supplied Materials

Plastic cable ties
AC wiring. Please refer to the cable recommendation chart in Chapter 1 (see
Table 15 AC Power Supply System Maximum Cable Lengths).
Explosion proof conduit with fittings and poured seals or approved explosion
proof/flame Proof Flexible Cable with Fittings according to the requirements
of the national and local codes.
Page 252 2101510-002 rev. AE

2X 3/4 CONDUIT ACCESS HOLE
9.63
10.12 9.12
7.37
10.67
10-24 GROUND LUG
Figure 256 Explosion Proof AC Power Supply Top/Front Dimensions
Figure 257 Explosion Proof AC Power Supply Side Dimensions
The installation must be performed by person(s) qualified for

the type and area of installation according to national and local
codes.
2.27.2 Instructions
1) The AC power supply is shipped separately. When the unit is received,
unpack and inspect all components for evidence of damage. Report
damage to the shipping carrier and to Totalflows service department.
2) Mount the explosion proof enclosure on a nearby wall or panel. Make sure
that the rigid explosion proof conduit or appropriate flexible conduit can be
installed between the power supplys explosion proof enclosure and the
NGC. Avoid obstructions.
3) Remove the necessary plugs from the side of the explosion proof enclosure
to install the rigid conduit.
2101510-002 rev. AE Page 253

Please review Grounding the NGC section in Chapter 1-
4) Pipe the conduit and associated AC wiring from the external power source
into the AC power supply enclosure.
5) Using the wiring instructions in Figure 258, make field connections from
the 115 VAC hot and neutral or the two hot wires for 230 VAC to TB1
terminal 5A and terminal 6A on the power supply.
instructions in Figure 258 make field connections from the power supply
wire from F1 terminal B to J1 connector (+) pin and connect the ground wire
TB1 terminal 1A to J1 connector (-) pin. DO NOT re-insert J1 connector to
the termination board.
8) Go to the DC power installation later in this chapter.
UNSECURE
SECURITY
S2
QUINT POWER
Figure 258 Explosion Proof AC Power Supply Wiring Instructions
2.28 110/240 VAC to 12/24 VDC Power Supply Installation
The power supply may be approved for classified hazardous

rating listed on the unit tag and install per the referenced
control drawing. Be sure to follow the requirements of the
national and local codes when installing the power supply.
Page 254 2101510-002 rev. AE

codes.
Figure 259 6200 Optional Equipment Enclosure with Power Supply
Communication
Shelf
DC + + - -
OK
PHOENIX
CONTACT
DC OK
Adjust
11.5-18VDC
L N G
Figure 260 6700 Optional Equipment Enclosure with Power Supply
2101510-002 rev. AE Page 255

The AC/DC power supply may be approved for classified
Verify the rating listed on the unit tag, and install per the
of national and local codes when installing the power supply.
codes.
2.28.1 Instructions
1) If configured, the optional equipment unit should contain an installed AC
power supply. The Optional Equipment Enclosure should be installed using
instructions shown previously in this chapter.
rigid conduit.
3) Pipe the conduit and associated AC wiring into the enclosure.
Please review the Grounding the NGC section in Chapter 1-

4) Using wiring instructions in Figure 261, make the field connections from
the 115 VAC hot and neutral or the two hot wires for 230 VAC to TB1
terminal 5A and terminal 6A on the power supply.
instructions in Figure 261, make field connections from the power supply
wire from F1 terminal B to J1 connector (+) pin and connect the ground wire
TB1 terminal 1A to J1 connector (-) pin. DO NOT re-insert the J1 connector
to the termination board.
7) Go to DC power installation later in this chapter.
UNSECURE
SECURITY
S2
AC 100-240VAC
CONTACT
PHOENIX
L N G
+ - -
11.5-18VDC
Input
DC OK
Adjust
OK
+
DC
Figure 261 AC/DC Converter Wiring Instructions
Page 256 2101510-002 rev. AE

2.29 24 VDC to 12 VDC Power Converter
The DC/DC power converter may be approved for classified
Verify the rating listed on the unit tag and install per the
of national and local codes when installing the power
converter.

codes.
2.29.1 Instructions
1) If configured, the optional equipment enclosure should contain an installed
converter. Enclosure should be installed using instructions shown previously
in this chapter.
rigid conduit.
3) Pipe the conduit and associated DC wiring into the enclosure.
Please review Grounding the NGC section in Chapter 1-

4) Using the wiring instructions in Figure 262, make field connections from
the 24 VDC(+) and (-) source to TB1 terminal 11A (+) and terminal 12A (-)
on the power supply.
instructions in Figure 262 make the field connections from the power
supply wire from the TB1 terminal 7A to the J1 connector (+) pin and
connect the ground wire from TB1 Terminal 8A to the J1 connector (-) pin.
DO NOT re-insert the J1 connector to the termination board.
2101510-002 rev. AE Page 257

S2
U U U
F
F USE
F USE
F USE
E
E
S S S
Figure 262 24 VDC/12 VDC Power Supply Converter
2.30 Battery Pack Installation

To extend the life of the battery pack, fully charge the battery
prior to installation. Systems using solar panels may not fully
charge the battery. Charging the battery quickly removes the
oxide buildup and improves the life of the battery.
DO NOT over charge the battery pack.
Page 258 2101510-002 rev. AE

TB6, SPARE
TB5, SPARE
TB4, SPARE
TB3, SPARE
TB1, BATT
TB2
Figure 263 Optional 6800 Enclosure with Battery Pack
Figure 264 24 VDC Dual Battery Pack Cable
2.30.1 Instructions
1) Insert the battery(s) into the battery compartment with the terminals facing
up (see Figure 263).
2) For the 24 VDC solar power system or the 24 VDC UPS power system, a
dual battery cable is provided with unit (see Figure 264).
Connect the battery 1 red wire lug to battery 1 positive terminal.
Connect the battery 1 black wire lug to battery 1 negative terminal.
Connect the battery 2 red wire lug to battery 2 positive terminal.
Connect the battery 2 black wire lug to battery 2 negative terminal.
3) For AC charging systems containing one or two batteries (see Figure 265),
connect battery cable to prewired power supply cable(s).
2101510-002 rev. AE Page 259

4) If system calls for a solar panel charging system, proceed to instructions for
solar panel later in this chapter.
Please review Grounding the NGC section in Chapter-1

( SELECT EITHER
)
6770 ENCLOSURE
(+) (+)
J15
J18 I/ O EXP
BATT J16 (-) (-)
DISPLAY
MMI
J13 CHARGER
INPUT (+)
J10 J7 J17
COMM2 COMM1 (-) 3- WAY
CONNECTOR
COMM 1
P/ N 2012907- 001
COMM 2
J6
J4
DIGITAL /IO B A
J19 KEYPAD (- ) ( + )
SECURITY
S1 J8
XFC/ XRC Bd.
(-)
NGC 8201 TERMINATION PANEL AUXPWR OUTPUT BATTERY(BT1)
XBT1
J20
(+)
J23
1
1 2 3 4 5 6 7 8 9 0
DIGITAL /IO POWER
J2 J1
(+)
(-)
(+) (-) (+) (-) (+) (-) (+) (-) (+)
(-)
(-)
S2
1 2 1 2
INPUTS OUTPUTS
J7
(+) 1A 1B
XMFR
(+) (-) 2A 2B (-)
3B
3A
4A 4B
TERM TERM 5A 5B (+)
J9 J11 6A
6B
TB1
AC+ SHLD GND A F1 B
AC-
SERIAL PORT1 J3 SERIAL PORT2

J8 J10 DC
115/ 230V FUSE
AC IN WARNING AC
DO NOT USE (-) OUT
RESET SWITCH
J5 SWITCH
ON OFF
(-) OUT
S1 UNLESS AREA IS (-)S
KNOWN TO BE
NON- HAZARDOUS (+)S
J6 (+)OUT
(+)OUT
POWER SUPPLY( ROTATED FOR CLARITY

)
Figure 265 Battery Pack with AC Power Supply Wiring Instructions
2.31 Solar Panel Installation

The solar panel is designed for outdoor mounting on a 2 extension pipe located
near the optional equipment enclosure (see Figure 266). Solar panel must be
mounted within 12 feet of unit (other cable lengths available). For wall mounted
units, it can be mounted on top or side of meter house.
Do not connect solar panel power cable to the unit unless

main battery pack has been connected.
If installation procedures are required for mounting solar

panel on top or side of meter house, customer should
contact Totalflow's Service Department; see Getting Help in
the Introduction section of this manual.
Page 260 2101510-002 rev. AE

2.31.1 Materials Supplied
Two solar panels
U-Bolts and fastening hardware
Solar panel cables (Standard is 12, other lengths are available)
Solar panel mounting brackets (if not already attached to solar panel)
2.31.2 Material not Supplied

Cable ties
One 9-inch extension of 2-inch pipe or other suitable length of pipe, threaded
on one end.
One 2-inch coupling.
Exercise caution when installing solar panel, so as not to
damage it. When mounted, solar panel will face up from
horizon at 50 angle.
Solar Panel
Mounting Bracket
U - Bolts
2 " Extension Pipe
Solar Panel
Cable
2 " Coupling
Figure 266 Typical Solar Panel Installation
2.31.3 Instructions
1) Attach 2 pipe coupling to top end of enclosure mounting pipe. Securely
tighten.
2) Install 2 pipe extension into coupling and securely tighten.
3) Check solar panels using digital voltmeter to verify polarity and output
voltage. Voltage will vary depending on amount of sun, angle to sun, etc
4) Install solar panels on mounting bracket, with provided hardware, if
required.
DO NOT connect other end of solar panel cable to board

until instructed to do so.
2101510-002 rev. AE Page 261

5) Attach solar panel mounting plates to top end of 2 extension pipe with U-
bolts and associated mounting hardware. Do not tighten U-bolts until solar
panels are correctly positioned.
6) For northern hemispheres, position solar panels facing south. For southern
hemispheres, position solar panels facing north. For optimum charging,
solar panels should not be in shadows for the majority of the day. Panels
should be kept clean for maximum charging.
2.32 Solar Power Pack

The power supply may be approved for classified hazardous

rating listed on the unit tag and install per the referenced
control drawing. Be sure to follow the requirements of the
national and local codes when installing the power supply.

codes.
2.32.1 Instructions
1) If configured, the optional equipment enclosure should contain an installed
power supply. The enclosure should be installed using instructions detailed
previously in this chapter.
2) Remove plug from access hole in equipment enclosure. Insert solar panel
power cable through an access hole on side of case. Allow enough power
cable for field wiring to solar charger connector pins 3 and 4.
Please review the Grounding the NGC8206 section in

Chapter 1-System Description before making power
connections.
3) Pipe the conduit and associated DC wiring from the NGC8206 into the
power supply enclosure. See Table 14 in Chapter 1 for wire sizes.
4) Field wire solar panel cables to solar charger inside the enclosure. Using
the wiring instructions in Figure 267, make the field connections.
Loosen terminal block securing screws, insert wire then retighten.
Connect solar panel (+) lead to pin 4 and (-) wire to pin 3 terminal.
Verify main battery pack is connected.
5) Following connection of solar panel power cable, secure cable to 2
extension pipe and mounting pipe cable with plastic tie-wraps provided.
6) Go to the DC Power Installation section later in this chapter.
Page 262 2101510-002 rev. AE

Refer to Manufacturers Wiring
Diagrams for Solar Panel connectivity
Solar Charger
Temp
Sensor
Load
Charging Disconnect
Solar Panel Solar Panel

Solar Battery Load
4
+
3
-
2
+
1
-
6
+
5
- PS1
SS-20L-24V
- + - +
(+) LOAD (+) WHT

BATT (+) RED
Fuse Block 2 2 2 1 1
2 2
1 1
Spares
(+) BATT (+) RED

BATT (-) BLK
To NGC
BATT (-) BLK
(-) Load (-) BLK
Jumper (BLK)
J1 Buss Bar
1 4
To Battery
Cable P1
(-)
Figure 267 24 VDC Solar Panel Power Supply
2.33 DC Power Installation

These instructions assume that all external wiring has been
completed to the point where connections have been made to
the field termination connector, but the connector has not
been plugged into the termination panel.
2.33.1 Instructions
1) If the installation includes the optional power switch:
Apply power to switch; turn switch to ON position.
2) If the installation includes the optional equipment enclosure with the optional
power supply:
Apply power to power supply.
3) If the installation includes a solar panel connected to a battery:
Plug in the charger regulator battery connector.
4) Test power using a multi-meter connected to the J1 terminals of the phoenix
connector:
12 Volt System: voltage is between 11.5 and 16.0 volts (see Table 14).
24 Volt System: voltage is between 21.0 and 28.0 volts (see Table 15).
If volts are within range, the power should be disconnected, the phoenix
connector inserted into the termination panel J1 connector and power re-
applied.
2101510-002 rev. AE Page 263

During Startup operations, the unit will require:
12 Volt System: 11.5 volts minimum.
24 Volt System: 21.0 volts minimum.
5) If the NGC8200 has the optional VGA screen, the unit will show Totalflow
Boot Loader followed by the navigational screen, when functional.
6) Unit will begin Start-up Diagnostics and oven stabilization. This completes
the hardware installation. Proceed to the next chapter, Start-up, to begin
unit setup and operation.
2.34 Remote Communication Installation

As remote communication installation is specific to the communication transceiver,
only basic information is supplied here. Additionally, wiring instructions should be
shipped with the unit. Both communication ports (serial port 1 and 2) can function
as RS-232, RS-422 or RS-485.
Table 21 shows serial port pin outs and termination settings.
Table 21 Port 1 and Port 2 Pin-Outs/Terminations
RS-232 RS-485 RS-422

PIN PORT 1 (J8) PORT 1 (J8) PORT 1 (J8)
1 Power Out Power Out Power Out
2 Ground Ground Ground
3 Switched Power Out Switched Power Out Switched Power Out
4 Operate Operate Operate
5 Not Used RRTS RTS
6 Request To Send Bus + Transmit Bus +
7 Transmit Data Bus - Transmit Bus -
8 Receive Data No Connection Receive Bus +
9 Clear To Send (CTS) No Connection Receive Bus -
PIN PORT 2 (J10) PORT 2 (J10) PORT 2 (J10)
1 Power Out Power Out Power Out
2 Ground Ground Ground
3 Switched Power Out Switched Power Out Switched Power Out
4 Operate Operate Operate
5 Not Used RRTS RTS
6 Request To Send Bus + Transmit Bus +
7 Transmit Data Bus - Transmit Bus -
8 Receive Data No Connection Receive Bus +
9 Clear To Send (CTS) No Connection Receive Bus -
TERMINATIONS PORT 1 (J9) PORT 2 (J11)
First or Intermediate Unit (RS-485) Pins 23 Pins 23
Last or Only Unit (RS-485) Pins 12 Pins 12
RS-232 Pins 23 Pins 23
Page 264 2101510-002 rev. AE

3.0 NGC8206 STARTUP
This chapter describes the minimum requirements to start up a newly installed
NGC system. Specific details to further customize the NGC are discussed in the
PCCU32 help files.
DO NOT open or remove covers, including the PCCU local
communications cover, unless the area is known to be non-
hazardous, including the internal volume of the enclosure.
Before beginning, complete the tasks outlined in Chapter 2 -

Installation.
3.1 PCCU32 Installation and Setup

Totalflows PCCU32 6.0 (or later) software is required to communicate with the
NGC8200. Previous versions of PCCU32 are not compatible with the NGC8200.
PCCU32 software running in a laptop Windows desktop environment offers the
most capabilities for programming the NGC. The Windows environment features
user friendly help files and easy to follow menus that enable the user to step
through many required choices.
The Totalflow NGC8200 hardware is designed using Windows Mobile technology
CE operating system; therefore, communication between a personal computer
and the NGC8200 may be accomplished using a USB cable. When this method of
communication is desired, Windows ActiveSync is required and supplied with
PCCU32.
3.1.1 Software Installation Instructions

1) Insert the PCCU32 disk into the PC drive. If the CD drive is set to auto play,
the installation program should begin; otherwise, click the Windows Start
button, and select Run. Within the Run dialog box, type the following:
D:\Disk1\setup.exe. D stands as the CD drive designation.
2) Follow screen prompts during installation. When asked to install ActiveSync,
the answer depends on whether the unit was shipped with a USB (default)
or a round RS-232 military type connector as the local port connector. This
is the connector on the outside of the unit with the round, explosion proof
cap. If USB, the user needs to place a check in the install ActiveSync box. If
communicating via RS-232, simply click the Next button. If communicating
with a PDA, ActiveSync is already installed, but this installation may contain
a later version allowing for a upgrade. To verify the version, open
ActiveSync, and click the Help icon. Within the help file, select About
Microsoft ActiveSync.
3) Another screen prompt will allows for the selection of the correct port for
communication: USB port for connecting via USB and serial port for
connecting via RS-232. If the PCCU software was previously installed and
the user selected a port and they are re-installing or upgrading, select Keep
Current Port.
2101510-002 rev. AE Page 31

4) The installation puts a PCCU folder on the Windows desktop with shortcuts.
The shortcuts are correct, assuming the install directory was not changed. If
the install directory was changed, the shortcuts will have to be changed to
the new directory path. If using a network, the NGC on the Network shortcut
will require a network ID or IP address. For a standalone desktop shortcut,
right-click on the shortcut, select Create Shortcut from the pop-up menu,
and drag it to the desktop.
3.2 Ethernet Installation and Setup

Installation of an NGC in a network environment may be implemented using the
following instructions. Some decisions may require input from the users network
administrator.
PCCU32 communication with the NGC over an Ethernet connection (TCP/IP)
requires the use of a hub, switch or router (see Figure 31). Ethernet (local)
communication in a remote area may also be utilized.
PCCU32 makes use of the Windows DHCP Utility. Dynamic host configuration
protocol (DHCP) can randomly assign a unique IP address within the defined
subnet mask. This utility also allows the user to define a more user friendly
network ID. This ID must be unique within the subnet mask; however, a new IP
address may be automatically assigned to the NGC ,if the NGCs power is cycled.
For this reason, it may be preferable to disable the DHCP.
Disabling the DHCP requires that a unique IP address be assigned, generally by
the network administrator.
Figure 31 Ethernet Connections
Page 32 2101510-002 rev. AE

3.2.1 TCP/IP Network Connection
Materials Required:
Ethernet Straight through Cable (see Figure 32).
Hub, Switch or Router and Associated Wiring to NGC (see Figure 31).
3.2.1.1 Instructions
1) Acquire TCP/IP Network Settings:
Click the Windows Start button. From the pop-up menu, select Run.
In the Run dialog box, type the program name CMD..
Press OK.
At the command prompt, type ipconfig /all (space after ipconfig).
Record the PC and LAN settings displayed for later use.
2) Make local connection to the NGC using either the USB or RS-232 cable to
do initial setup of the parameters.
3) From the Analyzer Operation screen in PCCU, click on Show Tree View
button in the upper left corner of the screen.
4) Click on Communications to show the communication setup screen.
5) Select the Network tab.
If using a Windows network, the user can use the network ID
feature. Network IDs are limited to 15 alphanumeric digits,
with limited special characters. Please see the Windows
help files for more information on naming computers.
End View Straight-Through Cable

Brown
1 8 8
Brown/White
7 7
Green
8 6 6
5 Blue/White 5
Blue
4 4
Green/White
3 3
2 Orange 2
1 Orange/White 1
Connector Clip
Not Used 8 1 TX+

Not Used 7 2 TX-
RX- 6 3 RX+
Not Used 5 4 Not Used
RX+ 3 6 RX-
TX- 2 7 Not Used
TX+ 1 8 Not Used
Figure 32 Ethernet Cable-Typical
6) Enable or disable the dynamic host configuration protocol (DHCP). To

disable the DHCP and assigned IP address, set to No and continue to the
next step; otherwise, select Yes and skip to step 6.
7) Enter the IP address assigned by the network administrator and subnet
mask, if different (default is 255.255.255.0).
2101510-002 rev. AE Page 33

8) When all desired changes have been made, select Send.
9) Reset the NGC by pressing the Reset button located on the termination
panel housed in the rear of NGC enclosure.
10) Verify the Ethernet communication:
Change to TCP/IP network cable.
From the Windows Start Menu, select Run. From the Run dialog box,
type CMD to open the Command window.
11) At prompt > type ping followed by a space, then either the network ID or
IP address, and press enter. A successful communication will show multiple
replies for the unit.
3.2.2 TCP/IP Local Connection
Material Required:
Ethernet Cross-Over Cable (see Figure 33).
1) Make local connection to the NGC using either a USB or RS-232 cable to
do the initial setup of the parameters.
End View Crossed-Over Cable

1
Brown Brown
8 8
Brown/White Brown/White
8 7 7
Green Orange
6 6
5 Blue/White Blue/White 5
Blue Blue
4 4
Green/White Orange/White
3 3
2 Orange Green 2
1 Orange/White Green/White 1
Connector Clip
Not Used 8 1 TX+

Not Used 7 2 TX-
RX- 6 3 RX+
RX+ 3 6 RX-
TX- 2 7 Not Used
TX+ 1 8 Not Used
Figure 33 Ethernet Cable-Cross-Over
2) From the Analyzer Operation screen in PCCU, click on Show Tree View
button in the upper left corner of screen.
3) Click on Communications to show the communication setup screen.
4) Select the Network tab. Enable DHCP. Send changes, and record a new IP
address for later use.
5) Exit PCCU, and disconnect the local communication cable.
6) Connect the Ethernet cross-over cable between the PC and NGC.
7) Open PCCU software. Click on Operate on the menu bar. Navigate through
the drop-down list to Setup. From the fly-out menu, select System Setup.
Page 34 2101510-002 rev. AE

8) Under Communications, set the PCCU com port to TCP, and enter the IP
address previously noted in the network ID or IP box. Close the System
Setup screen.
9) Verify the TCP/IP communications by clicking the Entry button on the main
screen (upper most left button).
If receiving a Communication Link Failed error message,

investigate the following possible causes:
Verify a crossover Ethernet is being used and not a
straight through Ethernet cable.
If using a network hub or network, verify the firewall is not
blocking the IP address.
If the laptop is connected to a network, verify a virtual
private network (VPN) is not being used to access a
corporate network. The VPN may need to be disconnected
before a local Ethernet connection is possible.
3.3 Connecting to NGC8206s Local Port

The laptop computer connects to the local port via USB or RS-232 using one of
two cables (See Figure 34).
ActiveSync software is required to communicate when
using a USB. If ActiveSync was not installed during the
PCCU32 installation, connecting the USB cable should
trigger the ActiveSync installation to begin.
3.3.1 Communicate Instructions

1) Connect the MMI cable to the designated port on the PC and to the local
port located on the outside of the NGC. If the unit is configured for the RS-
232 MMI cable, connect to the appropriate communication port on the PC
(default is COM1). If the unit is configured for a USB cable, connect the host
end of the USB cable to any USB port on the PC.
2) Although shortcuts were previously discussed, the following is the traditional
method of connection. Click on the Windows Start button. From the menu,
Programs and then PCCU (or correct program folder if changed during
installation). From the fly-out menu, select PCCU32. This will display
PCCU32s initial screen.
2101510-002 rev. AE Page 35

USB Cable RS-232 Cable
P/N 180 1800-xxx P/N 2015240-xxx
Figure 34 MMI Communication Cables
3) Assuming the MMI cable is connected, click on the Connect icon (left-most
icon at the top of the screen). If this unit had been previously set up, the
Local Connect screen would appear with some labeled buttons. However,
since going on the assumption that we are setting up the unit for the first
time, the NGC Startup Wizard will appear. If so, see NGC Startup on the
next page.
If the Invalid Security Code screen should appear, enter four
zeros (0000) for the new code, and click OK. The NGC
should have defaulted to 0000 on start-up.
4) Again, if the unit has already been set up, the Local Connect screen
displays two buttons: Entry Setup and Collect Historical Data. Clicking on
Entry Setup will takes the user to the Analyzer Operation screen which has
links to other operations. Daily operations should be performed from this
screen. Historical data collection can also be performed from here by
clicking on the Collect icon at the top of the screen.
If a communication error is received, click on the Setup icon

along the top of the screen, and verify the PCCU com port. If
using USB, this should indicate USB; if not, click on the down
arrow and scroll through the available selections, and select
USB. If the serial communications with the round connector
on the NGC end is used, select the communications port
being used (COM1, etc.). When finished, close the Setup
screen, and click the Connect icon again.
Page 36 2101510-002 rev. AE

3.4 NGC Diagnostics
Previously in Chapter 2-Installation, the DC power circuit to the NGC was
completed. Once power was applied to the unit, the NGC began the start-up
procedure:
Unit cold started, loading start-up information into RAM memory
Start-up diagnostics run. If diagnostics are not successful, unit will return a
system fault and cease start-up.
Start-up diagnostics consists of four areas of testing:
Stream Test
As noted above, the oven temperature test is one of the diagnostic tests run. To
pass this test, the oven temperature must reach 60 C and somewhat stabilize.
Additionally, part of the processor control test is testing the amount of effort the
oven controller takes to keep the oven at its set point of 60 C. Based on ambient
temperatures, this could take up to an hour. During this time, the user can be
entering information via the Startup Wizard.
During the initial start-up, all streams are disabled. During the stream test, streams
with input pressure will be re-enabled, tested and either passed or failed. Streams
with no initial input pressure will fail and are left disabled. Streams can always be
re-enabled later if they will be used.
During the diagnostics or upon completion, the user may view the status of the
diagnostic tests by clicking on the Diagnostics button on the Analyzer Operation
screen. Part of the startup diagnostic takes the user to the Diagnostic screen.
When the unit completes the startup diagnostics and has passed the appropriate
tests, with the exception of streams with no pressure, the unit will go into hold
mode. Totalflow recommends that the unit be allowed to run at least eight hours to
completely stabilize and then a calibration is performed. This is also spelled out in
the Startup Wizard.
3.5 NGC Start-Up Wizard

After starting PCCU32 and clicking the Connect icon as discussed earlier, the
NGC Startup Wizard begins automatically. This will only happen the first time the
user connects to the unit or each time they reconnect to the unit and have not
completed the Startup Wizard.
The wizard walks the user through the process of entering all the necessary
information to get the NGC up and running. Each screen has an associated help
screen that automatically displays when moving from screen to screen.
Step through all the screens in the Startup Wizard, filling in the required
information. The unit may be concurrently running the startup diagnostics as the
user is entering data into the Startup Wizard. One of the steps in the Startup
Wizard is displaying the Diagnostics screen to see the results. If the diagnostics
are still in progress, the Startup Wizard will not allow the user to continue until they
finish.
The following procedure is only an outline, and specific steps are discussed in the
Wizard help file.
2101510-002 rev. AE Page 37

3.5.1 Station Setup Instructions
1) Enter the Station ID (10 alphanumeric digits) and Location (24 alphanumeric
digits) (see Table 31). The Station ID should be a unique identifier from
other NGCs the user may communicate with.
2) Verify the date and time; if incorrect, Set Device with the PCCU Date/Time
to Yes.
Additional items in the Station Setup screen are not required
for start-up. For more information regarding the setup of these
items, see the topic on the start-up help displayed with each
screen.
3) When all desired changes have been made, select Send and then Next to
move to the next screen.
Table 31 Station Setup Screen Information
Description Value
Station ID Assign unique Identifier (10 alphanumeric digits)
Location Enter information regarding meter location (24 alphanumeric digits).
Date/Time Shows current unit Date/Time
Set Device with PCCU Date/Time Resets device Date and time to match PC
3.5.2 Stream Setup Instructions

1) Enter the Stream ID, Location, Contract Settings and Calculation Settings
(see Table 32).
2) When all the desired changes have been made, select Send and then Next
to move to the next screen.
3) Complete steps 1 and 2 for each sample stream.
During the stream setup, please note that each time Next is
selected, the user should see the Stream ID, located on the
first line of each screen, change value. The user must move
through all four streams even if the unit is a single stream
unit.
Page 38 2101510-002 rev. AE

Table 32 Stream Setup Screens
Setup Tab Available Values

Stream ID Assign unique Identifier (10 alphanumeric digits)
Enter information regarding meter location (24
Location
alphanumeric digits).
Stream #4 (default) Stream # 1, Stream #2, Stream #3 or
Calibration Stream
Stream (Any)
Contract Settings Value Available Units
KPa, InH20, Mbar, InHg, PSIA, Bar, mmHg, PSFa, MPa,
Contract Pressure 14.73 PSIA (default)
Pa or kgcm2
Contract Temperature 60.00 F(default) C, F, R or K
Relative Humidity 100.00 %(default) Percent
Contract Hour 0 (default) Hour (0-23)
Calculation Settings Value
Current Calculation File GPA-2172-1996(AGA8), ISO-6976-1995, etc.1
Sum IC5 & NeoC5 No (default), Yes
Default-User Defined with C6+ Reported, 47.466% C6
35.340% C7 17.194% C8, 50% C6 50% C7 0% C8, 50%
C6+ Index Split Mode2 C6 25% C7 25% C8, 57.143% C6 28.572% C7 14.285%
C8, User Defined C6+ Not Reported.
C6, C7, C8, C9, C10` Used to enter split percentages if desired.
3.5.3 Calibration Setup Instructions

1) Verify that each process stream is set up to use the correct calibration
stream (Stream 4 Default).
2) To make changes to the calibration stream for each process stream, use
the Back button to return to the setup for the stream and make changes.
3) Change Calibration Cycles Average and Purge Cycles, if required. Default
Calibration Cycles Average is 3 and Purge Cycles is 2.
4) Make changes to the concentrations in the % BLEND column insuring that
the Total Mole % equals 100%.
Caution should be used when entering component blend
percentages to carefully match the components labeled on
the calibration bottle. Mistakes will cause incorrect values.
If the Total Mole % does not equal 100% exactly, add or
subtract the remainder to or from methane (C1) to force the
total to 100%.
1 File selection automatically sets the remainder of items on this screen. See PCCU Help files for more
information.
2 Note that making a selection in this field (other than User Defined) will override any values in the C6+ Split
Percent area of the Stream Setup screen.
2101510-002 rev. AE Page 39

5) When finished and Total Mole % equals 100.00 %, select Next to move to
the next screen.
3.5.4 Diagnostics
1) As discussed earlier, diagnostics began when power was applied to the
unit. The user cannot proceed beyond the Diagnostics screen until
diagnostics have passed. When completed, select Next to move to the next
screen.
2) To change the run order of process streams, change values beside
Sequence Numbers. In this same screen, streams may be disabled or
enabled.
During the initial start-up, all streams will be disabled. During
the stream test, streams with an input pressure will be re-
enabled, tested and either passed or failed. Streams with no
initial input pressure will fail.
To enable or disable steams after completion of diagnostics,
select Stream Sequence from the Analyzer Operation
screen. Totalflow recommends that the diagnostic stream
test be preformed on streams enabled after initial
diagnostics. Select the help button for additional information.
3.5.5 Update Configuration

1) Totalflow recommends that the user save the unit configuration file following
setup. Change the value beside Save Configuration Data to Now to save
configuration.
2) Select Send and then Next to move to the next screen.
3.5.6 Analyze Calibration Stream

1) Prior to running the sample streams, the NGC should run the calibration
stream (default Stream 4). Select Stream 4 on the left side of the screen.
The button beside Stream 4 should illuminate, the cycle clock will begin,
and the user should see animated gas running on the calibration stream.
2) Allow the stream to process for two or three cycles (approximately 10 to 15
minutes). During the final cycle, change the next mode to Hold. When unit
completes the current cycle, it will enter hold mode.
3) Select Next to verify analysis results.
4) Compare normalized % for each component to component and percent
listed on the calibration blend bottle. Component percentages should be
relatively similar.
Page 310 2101510-002 rev. AE

There will not be any comparisons for C6+ individual
components. There may be values in the Normalized column
for hexane thru Decane, but this is based on the C6+
configuration entered in Stream Setup. For comparison
purposes, use the components called heavies.
5) Select Next to verify heavy components on Chrom-1.
6) Verify that the appropriate components are visible and labeled. For the
standard C6+ application, the user should see C6+, C3, IC4, nC4, neoC5,
iC5 and nC5. The 2nd peak from left that looks like two peaks is a
composite peak of C2- and is not used in calculations.
7) Select Next to verify light components on Chrom-2.
8) Verify that the appropriate components are visible and labeled. The user
should see N2, C1, CO2, and C2. The 1st peak on the left is a composite
peak of C3+ and is not used in calculations.
9) Select Next to begin the process stream analysis. Select Run on the left
side of the screen to begin the first process stream in the sequence. The
buttons beside Run should turn blue, the cycle clock will begin, and the user
should see animated gas running on the process stream.
3.5.7 Start-up Completion

1) The unit should continue to cycle through all enabled streams performing
analysis and producing data.
2) Totalflow recommends that the unit be allowed to run at least eight hours
before calibration to allow unit to stabilize.
3) Select Close to complete the Start-up Wizard and return to PCCUs Local
Analyzer Operation screen. If completed satisfactorily, the Start-up Wizard
should not re-appear when connecting to unit. However, should the user like
to review or make changes, they may re-enter the Wizard by selecting NGC
Start-up Wizard from the Help drop-down menu.
3.6 Calibrating the NGC

The NGC is factory calibrated and should not require that a calibration be
performed immediately. It is recommended the unit operate for a period of eight
continuous hours before a field calibration.
At that time, a field calibration should be performed. This will allow adjustments
due to the locations barometric pressure and other factors to be taken into
consideration.
A calibration cycle includes purge cycles and multiple calibration cycles for
averaging. System defaults to stream 4 (cal stream), two purge cycles and three
calibration cycles. When calibration is complete a thorough examination of the
results should follow.
Allow the NGC to run for a minimum of eight hours before a

field calibration is performed.
2101510-002 rev. AE Page 311

3.6.1 Instructions
1) From the Analyzer Operation screen, select Cal.
2) When the current cycle completes, the unit should begin a calibration on the
designated cal stream (stream 4 default).
3) When the calibration is complete, the unit should move to the designated
next mode. View results on the Analyzer Operation screen.
4) The calibration streams UnNormalized total should be 6.5% (between
99.5% and 100.5%).
If values exceed these parameters, proceed to the

Troubleshooting section of this manual.
5) Carefully examine the calibration streams Chrom-1 and Chrom-2 by

clicking on the button. Look for unlabeled peaks and base line
anomalies. Figure 35 and Figure 36 should be used as a guide.
If errors exist, proceed to the Troubleshooting section of this

manual.
6) Once the unit is running smoothly and is producing good chroms and all the
peaks are labeled and eluting correctly, perform a save and restore
procedure to update tfCold.
Figure 35 Typical Chromatograph for Chrom-1 (Heavies)
Page 312 2101510-002 rev. AE

Figure 36 Typical Chromatograph for Chrom-2 (Lights)
3.7 Security System

The NGC Board has a bi-level security system built in. For the purpose of this
manual, this is referred to as hardware security. When the NGC is accessed
through PCCU32 or WINCCU Host software packages, either remotely or locally,
there is a third level of security included. This is referred to as the software
security.
The security switch located on the termination panel of the NGC must be switched
down for the hardware security system to be functional. The switch must be
switched up to change the devices security code. Security codes are checked via
remote communication whether the switch is on or off.
3.7.1 Security Code
The setup, as designed, has each user log on to the system with a unique user
name (up to 25 alphanumeric digits) and 4-digit alpha-numeric password before
connecting to the unit.
3.7.2 Hardware Security
The hardware security system is designed to have two levels of user access: 1)
reading data files, read only access, and 2) sending application and
configurations, read/write access.
By default, user access is restricted from modifying the application table or from
downloading files to the devices TFData and TFCold drives, but has all other user
type privileges. These default privileges can be edited by the administrator and
consist of 4-digit alphanumeric pass codes, level 1 and level 2.
2101510-002 rev. AE Page 313

3.7.3 Software Security
The tri-level software security system is designed for the password administrator
to set up the accounts and privileges for themselves as well as all other host
software users. These privileges include being able to instantiate applications and
make changes to the functionality of the NGC.
A second level of user access includes application editing and downloading files to
a device. User access by default is restricted from modifying and downloading the
application table or from downloading files to the devices TFData and TFCold
drives but has all other user type privileges.
These default privileges can be edited by the administrator and consist of a user
name (up to 25 alphanumeric digits) and a password (up to 25 alphanumeric
digits).These are separate privileges and may be given individually or totally. See
the help files in the host software package for more information.
The NGC does not send an error message when the user
tries to write an operation but does not have the proper
hardware security code; it simply does not accept value
changes.
3.8 Alarm Definitions

The user has the ability to define the threshold for the NGC alarm parameters.
The NGC provides 124 standard alarms. Of these, a number of alarms are
defaulted to enabled (see Table 33). Many of these are considered system
alarms, and the user is cautioned not to make changes to the logic. A multitude of
additional alarms are available and user configurable.
User may define alarms, beyond defaults, for each process

stream.
Table 33 Defaulted Alarm Definitions
Alarm Descriptions Logic Type Threshold Severity

Default
Pressure Regulator 1 GT 0 Fault
Pressure Regulator 2 GT 0 Fault
Sample Pressure GT 0 Fault
Oven Temperature Error GT 0 System Fault
No Stream Valve Selected GT 0 System Fault
Digital-Analog Bd Comm Error GT 0 System Fault
Calculation Error GT 0 Fault
Calibration Un-Normalized Total GT 0 Fault
Stream Sequence Error GT 0 Fault
Calibration CV Percent Error GT 0 Fault
RF Pct Error GT 0 Fault
Analog Bd Ambient Temp GT 0 Warning
Analog Power Supply GT 0 Warning
Page 314 2101510-002 rev. AE

Alarm Descriptions Logic Type Threshold Severity
Default
Out of Carrier Gas (DI1) LT 1 System Fault
Out of Cal Gas (DI2) LT 1 System Fault
GCM Chrom Process GT 0 System Fault
Bad Bead GT 0 Fault
Sample Flow Detect GT 0 Fault
Cpu Loading GT 85 Warning
System Memory Available LT 500000 Warning
Ram File Available LT 1000000 Warning
Flash File Available LT 1000000 Warning
Missing Peak-Cal Not Used GT 0.0000 Warning
Stream Un-Normalized Total GT 0.000 Warning
2101510-002 rev. AE Page 315

B
Bllaannkk P
Paaggee
Page 316 2101510-002 rev. AE

4.0 MAINTENANCE
4.1 Overview
This chapter provides the user with maintenance information and instructions on
how to remove and install NGC components. Performance of the recommended
procedures maintains the unit in optimum operating condition, reduces system
downtime and ensures accuracy of natural gas sample analysis.
It is recommended that the user develop regularly scheduled daily, weekly or
monthly maintenance programs. By establishing such programs, NGC downtime
will be reduced and the system will operate at optimum analytical efficiency.
Perform all the recommended procedures as presented within this chapter. If
through use additional procedures are developed, they should be included with
those in existence.
Practical experience permits updating the maintenance procedures and
associated schedules over time. This results in many procedures being performed
on a routine basis before potential problem(s) result in a failure.

4.1.1 Help
If technical assistance is required during performance of maintenance functions or

if returning parts, the user should contact ABB Totalflow customer service
department at the following phone number:
4.1.2 Maintaining Cleanliness
It is important that an inspection time period be established to examine the unit for
internal and external cleanliness and damage.
Because an NGC installation is primarily exposed to external environmental
conditions, it is important that it be regularly inspected for cleanliness, both
externally and internally. Even though the NGC is tightly sealed against moisture
and foreign contamination, it is recommended that the internal components be
examined for moisture and/or contamination. If contamination is found, the system
should be shut down and cleaned. If such contamination is not removed, it could
render the NGC inoperable.
4.1.3 How to Use This Chapter
It is recommended that the user develop a regularly scheduled maintenance

program. By establishing a maintenance program, NGC downtime can be
minimized.
Record all items within this chapter in the maintenance practice procedures.
Practical experience permits updating this schedule over a period of time. This
results in many maintenance items being handled on a routine basis before
potential problem(s) result in a failure.
2101510-002 rev. AE Page 41

4.1.4 Returning Part(s) for Repair
If a Totalflow component is to be returned for repair, securely wrap it in protective

anti-static packaging. Before returning a component, call us for a return for
authorization number (RA). Affix this number to the outside of the return package.
Parts shipments must be prepaid by the customer. Any part, not covered by
original SYSTEM WARRANTY, will be shipped to the customer, F.O.B.
When the user removes the front or rear end caps, their
hands can become coated with a black thread lubricant. If
this happens, wash your hands before performing
maintenance functions, using Go-Jo or an equivalent type
hand cleanser. The lubricant MUST NOT come in contact
with components. DO NOT wipe lubricant on clothing as it
cannot be removed easily.
If enclosure needs more thread lubricant, use Vaseline.
4.2 Spare Part Components

The information in this section presents the user with the components (see Figure
41) and parts that are accessible for removal and installation. Replacement
components will be covered first in this chapter, followed by instructions for
replacing spare parts.
4.2.1 Replacement Components
The following is a list of components that may be replaced:

Analytical module (12 or 24 VDC) with or without GC module (see Figure 42)
GC module
Digital controller assembly with display
Termination panel
Feed-through assembly without preheat (see Figure 43)
Feed-through assembly with preheat (12 or 24 VDC)
4.2.2 Replacement Parts
The following is a list of parts that may be replaced:

Lithium Battery
Frit Filters
Analytical processor to termination panel cable
Termination panel to digital controller cable
Feed-through O-ring
Feed-through interface gasket
Feed-through manifold gasket
Feed-through heater (12 or 24 VDC)
GC module temperature sensor
Page 42 2101510-002 rev. AE

Figure 41 NGC8206 Overall View
2101510-002 rev. AE Page 43

Figure 42 Analytical Module, Exploded
Figure 43 Feed Through Assembly, Exploded
Page 44 2101510-002 rev. AE

4.2.3 Repair Time
ABB Totalflow has provided a recommended spares list for the NGC8206 product
line. Consideration was given to the cost of the repair time and the cost of stocking
the repair parts. The NGC8206s modular design is uniquely suited for quick repair
times. All the modules are easily replaced in a short time. Below are listed four
categories of repair times and the spares required to achieve those various repair
times. Repair days are in work days not calendar days.
Table 41 Repair Time vs. Down Time
Repair Time Requirements

If the application cannot allow for any down time, the
user will need to consider having two units up and
No down time
running. When one fails the user can simply switch to
the backup unit and send the failed unit in for repair.
If the user is required to have a down time of less than
eight hours, the user will have to stock replacement
parts on site. The repair parts required would depend on
In less than 8 hours
the variety of applications at the site. This would be a
typical scenario, if the user has multiple units or
applications at a single site.
This category is for applications where the parts would
be stocked at the factory. Over night delivery of the part
In less than 48 hours would allow for repair the next day. This might be typical
for a fixed application that could tolerate a 48 hour repair
time.
This category is suited for any application or mix of
In less than 120 hours applications. Within five working days, the site can
receive shipment of stocked or built-to-order parts.
4.2.4 Recommended Spares
Recommended spares are provided for each of these categories, depending upon
whether there is a single or multiple unit at the site(s) and whether the applications
are fixed applications (stocked at the factory). The user will need to balance the
cost of the spares with the cost of the repair time. With the variety of options
available, the user can manage the repair time for the units, as needed.
4.2.5 Customer Service
Customer service can be called out and may have the stocked applications
available for replacement (depending upon usage by the individual on service
calls). The scheduling for a call out is typically a week. As a result, maintenance
contracts may need to be considered, if service personnel are needed in a more
timely fashion. Phone support from the factory is available to help with diagnosis
of the problem. Alarms from the unit are also a key to quick diagnosis and repair
of any failure.
2101510-002 rev. AE Page 45

Table 42 Recommended Spare Parts
Stock Application
Part Description
1 >1
12 VDC Analytical Module Assy. w/o GC Module 1
12 VDC Analytical Module Assy. With GC Module 1
24 VDC Analytical Module Assy. w/o GC Module 1
24 VDC Analytical Module Assy. With GC Module 1
Cable between the Analog Processor and the Termination Board 1 1
Digital Controller Board & Display, Completed Assy. 1 1 per application
Digital Controller Board Assembly (Auxiliary unit with no display) 1 1 per application
Filter Frit for Feed-through Assembly 2 2
GC Module tested and characterized 1 per application
MMI Port RS-232 1 1
Ribbon Cable for connection between the Digital Controller and
1 1
Termination Panel
Termination Panel 1
USB Local MMI Port 1 1
4.3 Field Tool Kit

The recommended NGC maintenance tools are presented in Table 43 and are
included in the optional field tool kit.
Table 43 Tool Requirements
Qty -001 -002 Part Number Description

1 ( ( 2102304-001 Bag, ABB Nylon 11 x 6 Tool
1 ( 1800683-001 Cutter, 1/16 Tubing
1 ( ( 1801690-001 Extractor Tool, IC 8-24 Pin
1 ( ( T10790 Hex Key, Set 1/16-5/16 (12 Pcs)
1 ( ( T10440 Screwdriver, 3/32 x 2 Standard
1 ( ( T10601 Stripper, Wire
1 ( ( 1801821-001 Tool, Ball Driver, 10.3 Long, 5/16
1 ( ( 1801822-001 Tools, Nut Driver, 6 Shank,
1 ( 1801820-001 Wrench, 10 Adjustable
1 ( ( T10805 Wrench, 3/8 x 7/16 Open End
1 ( ( T10800 Wrench, 1/4 x 5/16 Open End
1 ( ( 1801819-001 Wrench, 6 Adjustable
Page 46 2101510-002 rev. AE

4.4 Visual Inspection
The NGC should be given an external visual examination on an established time
period. Visual checks maintain optimum system operation and accuracy of natural
gas sample analysis.
4.4.1 Inspection
During the visual inspection, components should be examined for the following
conditions:
Pipe or wall mounting: The unit must be in a vertical position and the
mounting brackets tightened on the pipe. The wall mounting bracket must be
securely affixed to the mounting wall.
Carrier gas bottle mounting rack: The mounting rack should be tilted
backward slightly to keep the bottles from falling forward.
Bottles within mounting rack: The bottles must be securely strapped in the
mounting rack.
Bottle regulators: These must be tightened securely and checked for leaks.
Pipe mounted sample probe: These must be securely mounted in the pipe
meter run using an approved probe adapter.
Stainless steel tubing connected between sample probe and NGC: These
must not be bent or closed off. The connections must be tight. Such
conditions impede the sample flow to NGC.
Tightness of front and rear end caps: Hand tightening gently is adequate.
Input/output terminations, external power or signal cable runs: All
input/output cable, power and signal conduit runs to Div 2 or non-hazardous
areas must be sealed per NEC codes.
4.5 Backing Up Configuration Files (Save)

Before beginning any maintenance on the NGC, the user should collect the data
and back up all configuration files to their laptops hard drive or a floppy disk. This
safeguards the data and allows for a re-start of the unit without the problems of re-
configuring the NGC should anything arise.
Although there are save buttons in the Entry Mode screens which allows the user
to back up entry mode data items, a complete system backup is only
accomplished by using the Save and Restore Utility. When using this utility to
backup files, the user should also download the files to the TFCold drive in case of
a cold start.
4.5.1 Instructions
1) Collect data from the unit.
2) While in PCCU, use the Save and Restore Utility found under File Utilities in
the Operate drop-down menu or by clicking the Save and Restore Utility
button on the toolbar.
3) In the Save and Restore window, click the Save Station Files button.
4) When the Save Station Files window appears, verify the default name and
path for the files. Click OK. This will save the TFData files to the PC.
2101510-002 rev. AE Page 47

5) When finished saving the station files, a new window will offer the option to
restore the station files to the TFCold drive. If the user selects Yes, the
station files will be downloaded to that drive.
It may not always be desirable to restore the station files to
TFCold. Some problems addressed in the Troubleshooting
section may require a selective restore. For more information,
see the Troubleshooting chapter and PCCU help files.
4.6 Restore Configuration Files

The Restore function enables the user to follow various maintenance procedures
or download configuration files to the flow computer.
If prior to performing maintenance, the Save Configuration Files was used, these
files were downloaded to the users laptop hard drive or on a floppy disk. The
Restore function uploads these files into the NGCs TFCold drive. This
safeguards the data and allows for a re-start of the unit without the problems of re-
configuring the NGC should anything arise.
4.6.1 Instructions
1) While in PCCU, use the Save and Restore Utility found under File Utilities in
the Operate drop down menu or by clicking the Save and Restore Utility
button on the toolbar.
2) In the Save and Restore window, click the Restore Station Files button.
3) When the Restore Station Files window appears, verify the default name
and path for the files. Click OK. This will restore the files to the TFCold
drive.
4) Perform a cold start following the instructions in the Reset Procedures
section and verify the unit is functioning properly.
It may not always be desirable to restore the station files to
TFCold. Some problems addressed in the Troubleshooting
section may require a selective restore. For more
information, see the Troubleshooting chapter and PCCU
help files.
4.7 Reset Procedures

On occasion, it may be necessary to reset the unit. There are two types of reset
procedures: warm or cold.
4.7.1 Warm Start Instructions
A warm start occurs when the main power is removed and then re-applied while
memory backup is enabled. This does not clear the data stored in RAM. The warm
start will only reset the NGC microprocessor and not disturb any data that has
been stored in RAM. A warm start can be used when a power or communication
interruption caused the NGC microprocessor to lock-up.
2) Using Lithium Battery Status instructions, verify the battery status is OK
before proceeding.
Page 48 2101510-002 rev. AE

3) Gain access to the rear termination panel on the NGC by loosening the
hex wrench and then unscrewing the end cap.
As with all electronic components, caution should be used
when handling boards. Static electricity can potentially
damage board components, voiding any warranty.
4) To warm start the unit, depress the S1 reset switch on the termination
panel.
Or, to remove the NGC from service, disconnect the power connector J1
from the board.
5) To place NGC in service, return the power connection J1 to the termination
panel.
4.7.2 Cold Start Instructions

1) On the Analyzer Operation screen, click Hold under Next Mode. When the
unit completes the current cycle and enters hold, the user may continue to
the next step.

2) Gain access to digital controller assembly by loosening the countersunk hex
socket locking set screw in the front end cap using a 1/16 hex wrench and
then unscrewing the end cap.
3) Gain access to rear termination panel on the NGC by loosening the
hex wrench and then unscrewing the end cap.
4) Unplug the lithium battery connector from the J5 receptacle on the digital
controller board (see Figure 44).
5) Push the Reset button located on the termination panel located in the rear
of the enclosure.
6) Initially, the Boot Loader screen will appear on front display.
7) When the Navigation screen appears, restore the lithium battery connection
on the digital controller board.
2101510-002 rev. AE Page 49

AB B
Figure 44 Digital Controller Complete Assembly
4.8 Restore Factory Defaults

Occasionally, it may be necessary to restore factory defaults. If critical
configuration data is accidentally changed or erroneous results have been
produced, the unit may require a reset to factory defaults. Inadvertently changing
setup data, including critical local communication protocols settings, may require
the user to revert all setup information (configuration data) to factory settings. This
includes the following items:
Communication port settings
Calibration gas concentrations
Instantiated applications
NGC setup information
Start-up wizard re-initialized
Electronic pressure settings
All application parameters including display changes
This procedure will require the user to delete both the TFData folder (current
setup data being used to operate the NGC) and tfCold folder (non-volatile
backup of the setup data).
This procedure should not be a normal operation. It should
only be used when all other setup and troubleshooting
options have been exhausted or used when a Totalflow
technical specialist recommends this procedure. If questions
exist, call Totalflow support at (800) 442-3097 option 2.
4.8.1 Instructions
the next step.
3) Shut-down PCCU32.
Page 410 2101510-002 rev. AE

The system may not allow the deletion of active files when
the NGC is in normal operation (running from FLASH);
therefore, the user should force unit into Boot Loader mode.
4) Force the NGCs operating system into Boot Loader.
5) a) Press the Reset button on the NGCs termination panel.
b) Wait about eight seconds until the Initializing System screen appears.
6) c) Press the Reset button a second time.
d) The unit should now be in Boot Loader mode. The screen will revert to
the TOTALFLOW display screen.
7) Right-click on the Activesync icon located in the System Tray on the PC.
From the pop-up screen, select Explore.
8) In the new window, highlight the TFData folder under Mobile Devices.
9) Right click and select Delete. The folder should disappear.
10) Open the Flash folder by double-clicking.
11) Highlight the tfCold folder. Right-click and select Delete. The folder
should disappear.
12) Press the Reset button on the termination panel. This action should cause
the \Flash\Factory\tfCold information, saved at the factory, to be copied into
a new TFData folder. This will restore all factory settings. The unit has
successfully been reset if the user sees the Startup Wizard when they
reconnect with PCCU.
4.9 Lithium Battery Status

Prior to some maintenance procedures, especially when a Cold Start is not
desirable or feasible, the user should verify that the Lithium Battery Status is OK.
If the user is directed to these instructions from another set of instructions, please
return to them when the status has been verified.
4.9.1 Instructions
1) While in the PCCU Analyzer Operation screen, select Station Setup from
the buttons across the top of the screen.
2) Select the value beside lithium battery status.
3) If Lithium Battery Status value reads OK, then power may be removed
from the unit without causing a cold start.
4) If Lithium Battery Status reads Low Voltage or Not Connected, then the
lithium battery should be connected or replaced prior to removing power
from the unit. See instructions later in the chapter, Replacing the Lithium
Battery.
4.10 Changing NGC Clock

When measurement streams are instantiated on the PGC, changing the clock
could affect the time when log period entries are made. To protect integrity of
accounting audit trails, the NGC handles these types of clock changes as follows:
2101510-002 rev. AE Page 411

Examples are based on a 60 minute Log Period.
4.10.1 Clock Change Not Crossing a Log Period Boundary

When the next log period entry is made, the clock is not altered.
Example: If the present time is 4:15 p.m. and the clock is changed to 4:05 p.m. of
the same day, the daily flow record is the same. The entry reflects the
accumulation over a 70 minute time period (15 minutes plus 55 minutes).
4.10.2 Forward Clock Change Crossing a Log Period Boundary
This forces a log period entry for part of the log period that has accumulated since
the last log period entry. NGC then advances to a new data flow record and
begins maintaining the balance of the days data in a newly defined boundary.
the same day, the entry reflects only a 55 minute average accumulation. Then a
new flow record is written and this period is also based on a 55 minute
accumulation.
4.10.3 Backward Clock Change Crossing a Log Period Boundary
This forces a log period entry for part of the log period that has accumulated since
the last log period entry. This is the same as for a forward clock change crossing
an hourly boundary. NGC advances to a new days data flow record and maintains
the balance of the days data in a new record.
the same day, the log period record entry reflects only a 5 minute average
accumulation (5:00 to 5:05). Then a new flow record is written and this log period
is based on a 5 minute accumulation (4:55 to 5:00).
A backward clock change uses two (2) daily records to
maintain data integrity. This assures that previously recorded
data is not overwritten.
If it is necessary to make small backward time changes, less
than one (1) hour, the user should wait until the current hour
has progressed far enough to make a change that does not
cross an hour boundary.
4.11 Replacing Calibration or Carrier Gas Bottle(s)

When calibration or carrier gas bottle(s) require replacement, please use the
following instructions.
4.11.1 Instructions
the next step.
2) Turn off calibration and/or carrier gas at the bottle.
3) Remove the regulator from the bottle.
4) Exchange the bottle with the full bottle.
Page 412 2101510-002 rev. AE

5) Re-Install the regulator into the bottle. Verify that the pressure regulator is
set correctly to either 15 PSIG for calibration gas or 90 PSIG for carrier gas.
Open the shut-off valve on the regulator.
6) At the NGC feed-through assembly, loosen the nut and ferrule from the
corresponding inlet, allowing air to purge from the line.
Be sure to follow the requirements of the national and local

codes when performing this purge.
7) Re-insert the ferrule and nut into the correct inlet and tighten.
8) Leak test connections at the bottle regulator and feed-through assembly.
9) In PCCU, with unit still in hold, run two single cycles. Inspect the
chromatograms to determine if the unit is processing correctly. If chroms are
OK, return the unit to normal operation.
4.12 Removing Digital Controller Assembly

This section presents the procedures for removal and installation of the digital
controller assembly and mounting bracket. If the user has been directed here from
another procedure, return back to the corresponding procedure when disassembly
is complete.
when handling boards. Static electricity can potentially damage
board components, voiding any warranty.
4.12.1 Instructions
the next step.
2) Gain access to the digital controller assembly by loosening the countersunk
hex socket locking set screw in the front end cap using a 1/16 hex wrench
3) Using a flat blade screwdriver, loosen the screw in the mounting clamp.
4) Unplug the ground cable from the digital controller assembly.
5) Slide the assembly off of the thermal flask, being careful to not unplug the
flat ribbon cable connecting the digital controller assembly to the termination
panel or the lithium battery.
DO NOT remove the NGC board mounted lithium battery or
the termination panel cable at this time. Removing the lithium
battery will cause a cold start and that may not be desirable.
When replacing the lithium battery, the termination panel
cable must remain connected to power the digital controller
assembly; otherwise, the unit will cold start. The user will
receive specific instructions during each procedure if either
cable should be unplugged.
6) To reassemble, perform steps 35 in reverse order, being careful to align
the display screen horizontally before tightening screw.
2101510-002 rev. AE Page 413

4.13 Replacing Digital Controller Complete Assembly
Access to the digital controller assembly is gained by removing the front mounted
digital controller assembly from the analytical module.
4.13.1 Instructions
the next step.
3) Back up the configuration files, following the instructions detailed previously
in this chapter entitled, Backing Up Configuration Files.
4) Turn off all sample streams, calibration gas and carrier gas.
5) Disconnect or remove the power from the NGC unit externally, or remove
the J1 connector from the termination panel.
6) Following the instructions detailed in this chapter entitled, Removing Digital
Controller Assembly, remove assembly.
7) Unplug the termination panel to digital controller assembly flat ribbon cable,
leaving the lithium battery connected.
SECURE DIGITAL CARD DRIVE
LCD INTERFACE
40 PIN CONNECTOR
JTAG INTERFACE
J2 14 PIN HEADER
U10
U11
1
2
J7
U20 U21
CPU
AUXILIARY INTERFACE J3
32 PIN CONNECTOR
13
14
U3
BOOT MODE U18 U19

1
NOT USER J5
1
CONFIGURABLE
J6
4
3
U14
LITHIUM BATTER
3 PIN HEADER
J1
2 50
1 49
TERMINATION INTERFACE
50 PIN CONNECTOR
Figure 45 Digital Controller Board
8) To reassemble using the replacement assembly, perform steps 67 in

reverse order, being careful to align the display screen before tightening.
Check the lithium battery plug for proper installation on the connector.
Page 414 2101510-002 rev. AE

Please note that the termination panel to digital controller
ribbon cable pin 1 wire is NOT red. On the digital controller
board, the red edge (pin 1) of the cable should plug onto pin
50, the right side of plug. The plug is keyed; do not force the
plug into the connector.
9) Re-plug the ground cable onto the new assembly.
10) Once assembled, apply power to the NGC (Step 5).
11) Adjust the contrast potentiometer R18 for optimum display. To adjust the
display contrast, use an extra small Phillips point screwdriver to turn the
potentiometer R18 clockwise for more contrast or counter clockwise for
less.
12) Restore the configuration files following the instructions detailed previously
in this chapter entitled, Restore Configuration Files.
13) Reinstall front and rear end caps.
For the purposes of returning this assembly to Totalflow

service for warranty or repair, please contact Totalflow
customer service for an RA number. Please keep the lithium
battery connected to the digital controller board for return.
Please note that since power was removed from this unit, the
NGC will perform start-up diagnostics and stabilize. If the user
has disabled the start-up diagnostics, they should be enabled
and power cycled to the unit. If the power has been withheld
from the unit for an unknown or lengthy period of time, a
complete start-up should be performed.
For more information on enabling the diagnostics in PCCU,
click the Diagnostics button and then the Help button.
4.14 Replacing Analytical Module

This section presents the procedures for removal and installation of the analytical
module. The module is a completely self-contained unit and is part of the
NGC8200. Read through all procedural steps before beginning disassembly.
Verify before beginning the procedure that the module is appropriately rated for
the system voltage. Compare the module voltage to the ID tag located on the side
of the enclosure.
When the analytical module is removed, the module should
be placed on a clean, dirt free work surface. Care should be
taken that gas ports be free from lint or dust particles.
Totalflow strongly suggests that the GC replacement module
be kept in a sealed, static free envelope until the last
possible moment before installation.
It is important that the bottom surface of the module be
placed on a clean, lint free cloth to prevent components from
being scratched, damaged or contaminated.
customer service for an RA number.
2101510-002 rev. AE Page 415

4.14.1 Instructions
the next step.
4) Using Lithium Battery Status instructions, verify the battery status is ok
before proceeding.

8) Following the instructions detailed previously in this chapter entitled, Digital
Controller Assembly Mounting Bracket, remove the assembly. If
weather/circumstances permit, the digital controller assembly may be
suspended by the cables to eliminate stress on the cable connections. Skip
to step 10.
9) Carefully unplug the cable to the termination panel, leaving the lithium
battery plugged in. Set the digital controller assembly aside on a clean, lint-
free surface.
10) Using a 5/16 hex wrench, loosen the mounting screw (see Figure 46)
holding the analytical module in place until the module can be slowly lifted
from the enclosure, taking care to not pull or stress wires attached to the
rear of the assembly.
11) Detach the analytical module rear face jack J1 and J4, if the auxiliary heater
is installed (see Figure 47).
12) Set module on a clean, lint-free surface.
13) Verify that the gasket on the feed-through assembly manifold interface is in
place, in good condition and free from metal filings or other contamination. If
the gasket has fallen off inside the enclosure or stuck to the GC module,
replace onto the feed-through manifold interface, ensuring that the gasket
does NOT cover the gas portholes.
14) Verify the S1 auxiliary heater switch is set to the correct position. If using
the auxiliary feed-through heater, set the position to Normal.
15) Insert the mounting screw into the analytical module.
16) Holding the new analytical module at the opening of the enclosure,
reconnect jack J1 and J4, if the auxiliary heater is installed (see Figure 47).
Page 416 2101510-002 rev. AE

Figure 46 Analytical Module
Figure 47 Analytical Processor Board
17) Carefully insert the module into the enclosure, rotating the module to ensure
the rear components clear the manifold interface on the inside area of the
feed-through assembly. The feed-through manifold interface and the
analytical module are keyed to ensure proper alignment.
18) When the analytical module is in place, tighten the mounting screw.
19) Reassemble the digital controller assembly using instructions previously
covered in this chapter.
2101510-002 rev. AE Page 417

20) Plug the termination panel to the digital controller ribbon cable into the
digital controller assembly.
50, the right side of plug. The plug is keyed; do not force
the plug into the connector.
21) Insert the lithium battery pack into the enclosure between the enclosure and
the thermal flask.
22) Turn on all sample streams, calibration gas and carrier gas.
23) Once the unit is reassembled, apply power to the NGC (Step 6).
24) Follow the Cold Start procedure in Chapter 4-Maintenance.
25) Reinstall the front and rear end caps.
Please note that since power was removed from this unit,
the NGC will perform start-up diagnostics and stabilize. If the
user has disabled the start-up diagnostics, they should be
enabled and power cycled to the unit. If power has been
withheld from the unit for an unknown or lengthy period of
time, a complete start-up should be performed.
4.15 Replacing GC Module

This section presents the procedures for the removal and installation of the GC
module. The module is a completely self-contained unit and is part of the
analytical module. Read through all procedural steps before removing the
assembly.
of the enclosure.
When the GC module is removed, the module should be
placed on a clean, dirt free work surface. It is important that
the bottom surface of the module be placed on a clean, lint
free cloth to prevent its base from being scratched or
damaged and the gas sample flow line openings be free of
foreign contaminants.
If the GC module is not being immediately replaced, put the
thermal flask back in place to prevent the mandrel from
being scratched or damaged and gas sample flow line
openings free of foreign contaminants. Also, be careful with
the miniature D type connector pins.
4.15.1 Instructions
the next step.
Page 418 2101510-002 rev. AE

4) Using Lithium Battery Status instructions, verify battery status is ok before
proceeding.
suspended by the cables to eliminate stress on cable connections. If so,
move to step 10.
battery plugged in, and set the digital controller assembly aside on a clean,
lint-free surface.
10) Unscrew the thermal flask counterclockwise (see Figure 48). When loose,
lift the flask from the unit. Set aside.
11) Unscrew the oven wall counterclockwise (oven wall may be hot). When
loose, lift the cylinder from the GC module. Set aside.
12) Using the extraction tool, remove the cable connectors from J1, J2 and J3
jacks. DO NOT pull the connectors from the board by wires.
13) Using a 9/64 hex wrench, loosen the mounting screw inside the center of
the assembly. When loose, lift the assembly from the manifold assembly.
Set aside on a clean, lint-free surface.
14) Verify that the manifold heater plate gasket is in place and in good
condition.
15) Carefully insert the replacement module onto the manifold assembly,
rotating the module to ensure that the key holes line up and the module
rests on the base. The unit should not turn once it is seated correctly.
16) When the GC module is in place, tighten the mounting screw.
17) Carefully restore the cable connectors to J1, J2 and J3 jacks, being careful
to not press against the wires attached to the connector head.
2101510-002 rev. AE Page 419

Figure 48 GC Module, Exploded View
18) Replace the oven wall onto the GC module, being careful to not pinch or
bind any of the cables. When fully on, turn the oven wall clockwise to
tighten.
19) Replace the thermal flask over the GC module. When the flask reaches the
mounting bracket, turn clockwise to tighten.
20) Reassemble the digital controller assembly using instructions previously
21) Plug the termination panel to the digital controller ribbon cable and then into
the digital controller assembly, if disconnected.
Please note that the termination panel to the digital controller

50, the right side of the plug. Plug is keyed; do not force
the thermal flask.
23) Turn on all sample streams, calibration gas and carrier gas.
25) Follow the Cold Start procedure in Chapter 4-Maintenance.
Page 420 2101510-002 rev. AE

NGC will perform start-up diagnostics and stabilize. If the
enabled and power cycled to the unit. If power has been
4.16 Replacing Termination Panel

This section presents the procedures for removal and installation of the power
termination panel. This panel is located in the rear of the NGC. Read through all
procedural steps before removing the assembly.
4.16.1 Instructions
the next step.
2) Collect data from unit.
3) Back up configuration files, following the instructions detailed previously in
this chapter entitled, Backing Up Configuration Files.
4) Using the Lithium Battery Status instructions, verify the battery status is ok
before proceeding.
5) Gain access to the rear termination panel of the NGC by loosening the
hex wrench, and then unscrewing the end cap.
6) Disconnect or remove power from the NGC unit externally, or remove the J1
connector from the termination panel (see Figure 49).
7) Disconnect all connectors from board J2 digital I/O, J8 and J10 serial ports,
J3 Ethernet and J6 USB client connectors. Move the wires out of the way.
8) Using a 5/16 nut driver, loosen and remove the six nuts holding the
termination panel in place.
9) Lift the clear protective overlay out.
10) Lift the termination panel out, being careful of the wires fed into the
enclosure through the hubs and the cables connected to the back. DO NOT
REMOVE EMI GASKET.
11) Carefully unplug the ribbon cable to the digital controller from the back of
the termination panel J4 and the analytical processor J12. Set panel aside.
Please note that the termination panel to the digital
controller ribbon cable pin 1 wire is NOT red. On the
termination panel, the red edge (pin 1) of cable should plug
onto pin 50, the right side of the plug. The plug is keyed;
do not force plug into the connector.
2101510-002 rev. AE Page 421

DIGITAL I/O
POWER
VOLTAGE
SECURITY SWITCH J2 REGULATOR
S2 J1 VR1
(-) (+) (-) (+) (-) (+) (-) (+)
UNSECURE
(-) (+)
1 2 1 2
INPUTS OUTPUTS
D1 ETHERNET
LOCAL SERIAL DATA 5VDC POWER
CONNECTION D2 RECEPTICAL J12
SERIAL PORT 2
SERIAL PORT 1 TERMINATION
TERMINATION J7
J9 J11
1 3 J3 1 3 SERIAL PORT 2
SERIAL PORT 1
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
J8 J10
J5 SECURITY
ENABLED
D12 D11 D13
S1
D3 D4
USB HOST RECEPTICAL J6 STATUS ANALYTICAL PROCESSOR
STAT CONNECTION J4
LAN
LINK
USB CLIENT RECEPTICAL
RESET
ETHERNET STATUS INDICATORS DIGITAL CONTROLLER
SECURITY CONNECTION
SWITCH STATUS
Figure 49 Termination Panel
12) Holding the replacement panel at the opening of the enclosure, reconnect
the ribbon cable to the digital controller into the back of the termination
panel J4 and the analytical processor cable into J12.
13) Insert the termination panel into the enclosure being careful to not pinch the
wires between the mounting stud and the panel.
14) Replace the clear protective overlay into the enclosure on the mounting
studs.
15) Replace the nuts to hold the termination panel in place.
16) Restore J2, J8, J10, J3 and J6 connections, if applicable.
enabled and power cycled to the unit. If the power has been
Page 422 2101510-002 rev. AE

4.17 Replacing Feed-through Assembly
This section presents the procedures for the removal and installation of the feed-
through assembly. This assembly is located on the side of the NGC. Read through
all the procedural steps before removing the assembly.
of the enclosure.
4.17.1 Instructions
the next step.
before proceeding.
hex socket locking set screw in the front end cap using a 1/16 hex wrench,
suspended by the cables to eliminate stress on the cable connections. If this
is the case, move to step 10.
battery plugged in. Set the digital controller assembly aside on a clean, lint-
free surface.
10) Using a 5/16 hex wrench, loosen the mounting screw holding the analytical
module in place until the module can be slowly lifted from the enclosure,
taking care to not pull the wires attached to the rear of the assembly.
is installed.
12) Set the module on a clean, lint-free surface.
13) Using a open end wrench, loosen the Valco nut and remove the input
line. Repeat for all the sample, carrier and calibration gas lines.
14) Using a 5/64 hex wrench, loosen the feed-through set screw.
15) Unscrew the feed-through assembly, turning by hand counterclockwise until
free.
2101510-002 rev. AE Page 423

16) On the replacement assembly, install o-ring and manifold gasket supplied
with new feed-through assembly (see Figure 410).
17) Carefully apply the sealing thread lubricant to the threads on the feed-
through assembly, being extremely careful to not contaminate the feed-
through manifold and gasket.
18) Verify the O-ring and feed-through manifold gasket are in place and not
damaged (see Figure 410).
Figure 410 Feed-Through Assembly
19) Insert the replacement feed-through assembly through the opening and
screw in clockwise until completely screwed in but not tight.
20) Reverse the direction, unscrewing the feed-through assembly counter
clockwise a minimum of 1/2 rotation but no more than 1 1/2 rotations,
stopping when the flat edge is exactly on top and horizontal.
21) Using a 5/64 hex wrench, tighten the feed-through set screw.
23) Holding the analytical module at the opening of the enclosure, reconnect
jack J1 and J4, if the auxiliary heater is installed (see Figure 47).
feed-through assembly. The feed-through manifold interface and analytical
module are keyed to ensure proper alignment.
26) Reassemble the digital controller assembly, using instructions previously
27) Plug the termination panel to the digital controller ribbon cable and into the

Page 424 2101510-002 rev. AE

the thermal flask.
Please note that since the power was removed from this unit,
4.18 Replacing Lithium Battery

This section presents the procedures for the removal and installation of a new
lithium battery. The lithium battery is inside of the front end cap and is wedged
between the thermal flask and the enclosure wall. Read through all procedural
steps before removing the assembly.
4.18.1 Instructions
DO NOT REMOVE POWER TO THE UNIT! Loss of power to
the unit will perform a cold start. All data and configuration
files will be destroyed.
the next step.
when handling the boards. Static electricity can potentially
and then unscrewing the end cap.
5) Unplug the lithium battery connector from the J5 receptacle on the digital
controller board (see Figure 411).
6) Plug in the replacement lithium battery to J5 on the digital controller board.
the thermal flask.
8) Using Lithium Battery Status instructions, verify that the battery status is ok
before proceeding.
9) Reinstall the front end cap.
2101510-002 rev. AE Page 425

SECURE DIGITAL CARD DRIVE
LCD INTERFACE
40 PIN CONNECTOR
JTAG INTERFACE
J2 14 PIN HEADER
U10
U11
1
2
J7
U20 U21
CPU
13
14
U3
BOOT MODE U18 U19
1
NOT USER 1 J5
CONFIGURABLE
J6
4
3
U14
LITHIUM BATTER
3 PIN HEADER
J1
2 50
1 49
TERMINATION INTERFACE
50 PIN CONNECTOR
Figure 411 Primary Component Side Digital Controller Board
4.19 Replacing Frit Filters

Several reasons exist for replacing the frit filters from a scheduled maintenance
procedure to decrease sample pressure due to clogged filters. When replacing the
filters on a regularly scheduled maintenance plan, it will most likely not require that
the sample lines be removed from the external plate. When replacing the filters as
a troubleshooting measure, the user should remove the sample input lines and
use compressed air to clear the pathway. For the purposes of this manual, these
instructions contain steps for the worst case scenario.
4.19.1 Instructions
the next step.
4) Turn off all the sample streams, calibration gas and carrier gas.
5) Using a 7/32 hex wrench, loosen and remove all 8 hex socket screws
(see Figure 412).
6) If space permits, lift the external plate away from the internal plate and view
the frit filters. If space does not permit lifting the plate away enough to view
the filters, the user must remove the sample input lines and the carrier and
calibration gas lines.
7) If the filters appear soiled, it will be necessary to remount the external plate,
and remove the input lines. To remove the input lines, continue to the next
step; otherwise, move to step 8.
Page 426 2101510-002 rev. AE

OPTIONAL FEED-THROUGH
HEATER CABLE
INTERNAL PLATE
FEED-THROUGH
MANIFOLD GASKET
FEED-THROUGH
INTERFACE GASKET
EXTERNAL PLATE
SILICONE O-RING
.5 MICRON INPUT
FRIT FILTERS
MOUNTING HOLES FOR

1/4" SST HEX SOCKET
SCREWS
Figure 412 Feed-through Assembly, Exploded View
8) Using a open end wrench, loosen the Valco nut, and remove the input
line. Repeat for all sample, carrier and calibration gas lines.
9) Remove the 8 hex socket mounting screws.
10) Remove the used filters from the filter sockets. Using an edged instrument
or fingernail, put pressure on the outermost edge of each filter to pop them
out.
11) If replacing filters due to clogging, the user should also use compressed air
to blow out the input holes in the external plate. It may also be necessary to
wipe clean the gasket located on the internal plate; otherwise, move to the
next step.
12) Using the replacement filter, carefully lay the filter into the filter socket,
applying uniform pressure to the filter. DO NOT use any pointed instrument
to push the filter into place. Repeat for each input stream, carrier and
calibration gas input. Vents do not require filters.
13) Reseat the external plate, aligning the mounting pins on the internal plate to
the corresponding holes on the external plate.
14) Replace the 8 mounting screws, using a star pattern when tightening
the screws.
15) If the sample, carrier and calibration gas lines were removed, purge the air
from the transport tubing, and reconnect to the corresponding ports.
DO NOT over tighten. After securing the tubing, check for gas
leaks.
2101510-002 rev. AE Page 427

4.20 Replacing Feed-through Interface Gasket
Should the feed-through interface gasket require replacement (see Figure 412),
follow these instructions. Typically, the user would change the gasket while
performing another procedure, but for the purposes of this manual, the instructions
will start and finish as a complete procedure.
4.20.1 Instructions
the next step.
5) Using a 7/32 hex wrench, loosen and remove all 8 hex socket screws.
6) If space permits, lift the external plate away from the internal plate and
remove the damaged gasket from the internal plate. If space does not
permit lifting the plate away enough to replace the gasket, the user must
remove the sample input lines and the carrier and calibration gas lines.
7) Remount the external plate and remove the input lines. To remove the input
lines, continue to the next step; otherwise, skip to step 8.
8) Using a open end wrench, loosen the Valco nut and remove the input
line. Repeat for all sample, carrier and calibration gas lines.
9) Remove the 8 hex socket mounting screws.
10) Remove the damaged gasket from the internal plate.
11) Clean the gasket area on the internal plate using a clean, dry lint-free cloth
before placing the new gasket on the internal plate. The gasket is keyed to
ensure that it is placed correctly. The gasket should not cover any holes in
the internal plate.
12) Reseat the external plate, aligning the mounting pins on the internal plate to
the corresponding holes on the external plate.
13) Replace the 8 mounting screws, using a star pattern when tightening
the screws.
14) If the sample, carrier and calibration gas lines were removed, purge air from
the transport tubing, and reconnect to the corresponding ports.
DO NOT over tighten. After securing the tubing, check for gas
leaks.
4.21 Replacing Feed-through Manifold Gasket

Should the feed-through manifold gasket require replacement (see Figure 412),
follow these instructions. Typically, the user would change the gasket while
performing another procedure, but for the purposes of this manual, the instructions
will start and finish as a complete procedure.
Page 428 2101510-002 rev. AE

4.21.1 Instructions
the next step.
before proceeding.
6) Disconnect or remove power from the NGC unit externally, or remove the J1
connector from termination panel.

Controller Assembly Mounting Bracket, remove assembly. If
suspended by the cables to eliminate stress on cable connections. If this is
the case, move to step 10.
lint-free surface.
taking care to not pull the wires attached to the rear of the assembly.
11) Detach analytical module rear face jack J1 and J4 if auxiliary heater is
installed.
13) Replace the gasket on the feed-through assembly manifold interface,
ensuring that the gasket does NOT cover the gas port holes.
jumper J1 and J4, if the auxiliary heater is installed (see Figure 47).
feed-through assembly. The feed-through manifold interface and the
analytical module are keyed to ensure proper alignment.
18) Reassemble the digital controller assembly, using instructions previously
2101510-002 rev. AE Page 429

19) Plug the termination panel to the digital controller ribbon cable into the
Please note that the termination panel to the digital controller

20) Insert the lithium battery pack into the enclosure, between the enclosure
and the thermal flask.
21) Once the unit is reassembled, apply power to the NGC8201 (Step 6).
NGC8201 will perform startup diagnostics and stabilize. If the
user has disabled the startup diagnostics, it should be enabled
and power cycled to the unit. If the power has been withheld
from the unit for an unknown or lengthy period of time, a
complete startup should be performed.
4.22 Replacing Termination Panel to Digital Controller Cable

Should the termination panel to digital controller cable become damaged and
require replacement, follow these instructions. Typically, the user would change
the cable while performing another procedure, but for the purposes of this manual,
the instructions will start and finish as a complete procedure.
4.22.1 Instructions
the next step.
3) Back up the configuration files following the instructions detailed previously
before proceeding.

when handling the boards. Static electricity can potentially
and then unscrewing the end cap.
Page 430 2101510-002 rev. AE

8) Following the instructions detailed previously in this chapter entitled,
Removing Digital Controller Assembly, remove the assembly (see Figure 4
4). If weather/circumstances permit, the digital controller assembly may be
suspended by the cables to eliminate stress on the cable connections; the
user may skip to step 10.
lint-free surface.
taking care to not pull the wires attached to the rear of the assembly (see
Figure 47).
is installed.
13) Reach into the enclosure through the front opening, and unplug the ribbon
cable from the rear of the termination panel J4.
14) On the replacement cable, verify the orientation by viewing the keyed
receptacle on the termination panel and cable. Insert the plug into the J4
connector.
15) Verify that the gasket on the feed-through assembly manifold interface is in
place and in good condition. If the gasket has fallen off inside the enclosure
or is stuck to the GC module, replace onto the feed-through manifold
interface, ensuring that the gasket does NOT cover the gas portholes.
jack J1 and J4, if the auxiliary heater is installed (see Figure 46).
that the rear components clear the manifold interface on the inside area of
the feed-through assembly. The feed-through manifold interface and
analytical module are keyed to ensure the proper alignment.
20) Reassemble the digital controller assembly using the instructions previously
21) Plug the termination panel into the digital controller ribbon cable and then
into the digital controller assembly.

50, the right side of the plug. The plug is keyed; do not force
plug into connector.
22) Insert the lithium battery pack is into the enclosure between the enclosure
and the thermal flask.
2101510-002 rev. AE Page 431

Please note that since the power was removed from this unit,
4.23 Replacing Analytical Processor to Termination Panel Cable

Should the cable connecting the analytical processor to the termination panel
require replacement, use the following instructions.
4.23.1 Instructions
the next step.
3) Back up the configuration files following the instructions detailed previously
before proceeding.
As with all the electronic components, caution should be
used when handling boards. Static electricity can potentially
damage the board components, voiding any warranty.
6) Following the instructions detailed previously in this chapter entitled,
Replacing Termination Panel, remove the panel and unplug the cable.
Reaching into the enclosure, unplug the analytical processor to the
termination panel cable from the analytical processor assembly (see Figure
47).
7) Using the replacement cable, insert it into the enclosure, and plug into the
power/communication connector, J1. Connect the cable to the back of the
termination panel J12 connector (see Figure 49).
8) Reinstall the termination panel.
50, the right side of the plug. The plug is keyed; do not
force plug into connector.
10) Reinstall the rear end cap.
Page 432 2101510-002 rev. AE

2101510-002 rev. AE Page 433

B
Bllaannkk P
Paaggee
Page 434 2101510-002 rev. AE

5.0 TROUBLESHOOTING
5.1 Overview
As an aid to troubleshooting the NGC, this chapter will provide troubleshooting
guidelines for the various subsystems of the NGC. Some of these procedures will
differ slightly from other Totalflow products because the communications, power
charger/source and other I/O are contained in a separate enclosure rather than
within the NGC enclosure.
Some of the procedures are based on tests performed on the NGC termination
panel and others are based on tests performed on components located in a
separate enclosure. The user will determine which of these procedures
correspond to their particular unit. If using equipment other than the Totalflow
enclosure, the user will need to refer to the manufacturers procedures for
troubleshooting their equipment.
5.1.1 Troubleshooting Support
If troubleshooting instructions do not lead to a resolution and assistance is

required, the user can contact the Totalflow service department.
USA: (800) 4423097 or International: 001918-338-4880
5.1.2 Getting Started
Using Figure 51, determine which section most likely needed to begin and skip to
that section.
2101510-002 rev. AE Page 51

START
Go To
Startup YES During YES Receive
Return to Diagnostics
Startup? Alarm?
Start
NO NO
Go To
Return to Troubleshooting
Start Alarm
Go To
Power Supply
Return to Troubleshooting YES Batteries
Start Chart Dead?
NO
Go To
COMM
Troublelshooting YES COMM
Return to
Start Chart Trouble?
NO
Call Totalflow
Technical YES Still Having
Support Trouble?
NO
END
Figure 51 Troubleshooting Flowchart
Page 52 2101510-002 rev. AE

5.2 Start-Up Diagnostic Troubleshooting
This section focuses on determining what has caused an alarm during start-up
diagnostics. The Totalflow NGC8200 has an extensive built-in list of tests which
are performed each time the unit is started. This start-up testing may be disabled,
but Totalflow recommends that it be left enabled.
These diagnostics consist of 4 areas of testing:
Stream Test
These start-up tests may also be performed on a regular schedule. Please see the
PCCU help files for more information on scheduling diagnostics.
Totalflow has endeavored to perform extensive testing on
each NGC8200 prior to shipment, and each unit is factory
calibrated using our standard calibration blend.
During the stream test, streams with no gas pressure will
fail, and they will be disabled in the stream sequence. To
enable these streams, please click on the Stream Setup
button on the Analyzer Operation screen.
5.2.1 Status
The following description status and definitions are standard for all start-up
diagnostics. Additionally, each test group will have status results that will narrow
down the possibilities for troubleshooting.
Status Description
Idle No tests are running.
In Progress Test(s) are in progress.
Passed Basic and/or additional tests, if required, passed.
The basic test failed plus additional more in-depth tests

Failed
were run and also failed.
Tests were aborted by the user using the Abort

Aborted
command.
5.2.2 Carrier Pressure Regulator Test
If Col 1 or Col 2 carrier pressure test failed, the following procedure will step the
user through the troubleshooting process. On occasion, these instructions may
detour to other procedures, and, when complete, the user should return to these
procedures to continue.
5.2.2.1 Description
These alarms are indicative of low carrier pressure. The causes range from a
closed carrier bottle regulator to a blockage inside the GC module.
2101510-002 rev. AE Page 53

5.2.2.2 Status
The following descriptive status and definitions are applicable for only the carrier
pressure regulator test and are in addition to those defined for all start-up
diagnostics.
Status Description
Pressure is too low to continue the test. Possible causes

are the carrier bottle is low, the regulator on the carrier
Low Reg Pressure
bottle needs to be turned up to 90 PSIG, carrier line from
the bottle to the NGC is plugged, etc.
A blockage was sensed during one of the tests. The flow

Flow Blocked test was run in an attempt to dislodge the blockage but
was not successful. See flow test below.
This is an additional test that is in progress because the

Pressure Reg Test basic test failed. A different status will be displayed after
the test has finished.
The flow test is in progress. The flow test is initiated when

a blockage is sensed. The flow test will raise the pressure
Flow Test
in an attempt to blow the plug out through the vent. If
unsuccessful, the flow blocked status will be display
The additional tests can not prove with certainty but

Failed
either the GC module or the manifold assembly is bad.
1) Verify the carrier gas bottle pressure regulator is open. If not, open the
regulator on the carrier gas bottle. Otherwise, continue to the next step.
2) Verify the carrier gas bottle pressure regulator set point is 90 PSIG. If not,
correct the set point to 90 PSIG (620.5 kPa or 6.2 bars).
3) Perform the column vent pressure test procedure in this chapter for both
column vent 1 and column vent 2. If either test failed, proceed to the next
step.
4) Using the Replacing Analytical Module Assembly instructions in Chapter 4 -
Maintenance, replace the analytical module assembly.
Page 54 2101510-002 rev. AE

Totalflow recommends that a replacement analytical module
be installed at this point and additional steps be performed in
a clean, lint free atmosphere. Because the customer does
not have the required equipment to determine which specific
module needs replaced, the final instructions are by process
of elimination, beginning with the most likely module.
The Totalflow repair department offers a range of services
for troubleshooting and repairing/replacing the non-
functioning parts. For more information regarding the repair
service, contact customer service:
5) Using the Replacing GC Module instructions in Chapter 4-Maintenance,
replace the GC module.
5.2.3 Oven Temperature Test
If the oven temperature test failed, the following procedure will step the user
through the troubleshooting process. On occasion, these instructions may detour
the user to other procedures, and, when complete, they should return to these
5.2.3.1 Description
This alarm is indicative of a temperature condition. The causes range from an
unplugged cable to a bad module heater.
1) Verify that the cable is plugged in and in good repair. If the cable is
unplugged, plug-in the cable.
2) Verify that the analytical processor to GC module cable is plugged in and in
good repair. If the cable is unplugged , reinstall plug. If cable appears to be
damaged, continue to the next step.
3) Using the Replacing Analytical Module Assembly instructions in Chapter 4-
be installed at this point, and additional steps be performed
in a clean, lint free atmosphere.
The Totalflow repair department offers a range of services
for troubleshooting and repairing/replacing the non-
functioning parts. For more information regarding the repair
service, contact customer service:
2101510-002 rev. AE Page 55

5.2.4 Processor Control Test
If Col 1 or Col 2 carrier pressure test failed, or the oven temperature test failed,
the following procedure will step the user through the troubleshooting process. On
occasion, these instructions may detour to other procedures, and when complete,
the user should return to these procedures to continue.
5.2.4.1 Description
These alarms are indicative of a lack of ability to control a function. If the failure is
either one or both of the column carrier pressure tests, it could be a missing or
failed gasket. If the failure is in the oven control temperature test, it could be
something as easy as a missing GC module cover or analytical module thermal
flask.
1) If the start-up diagnostics are being performed following the
disassembly/replacement of a module or spare part, insure that the unit is
completely reassembled, including the thermal flask and both the front and
rear end caps, and re-start the diagnostics. If diagnostics again fail, repeat
disassembly steps and verify that all gaskets and connections are tight and
correctly installed.
2) If the start-up diagnostics are being performed from an initial startup, verify
that the analytical module is not loose inside the enclosure.
3) Verify that the GC module is tight and that the cables are correctly installed
and not damaged.
4) Reassemble the unit and restart diagnostics. If the unit continues to fail,
replace the entire analytical module and return to Totalflow for warranty
repair/replacement.
5.2.5 Stream Test
The stream flow diagnostics go through a series of tests, testing the stream
pressure at different conditions as listed below. Each column will display the
pressure results after that part of the test has completed. The status column will
reflect the current and final status of the tests.
The following procedure will step the user through the troubleshooting process.
On occasion, these instructions may detour the user to other procedures, and,
when complete, they should return to these procedures to continue.
During the stream test, streams with no gas pressure will fail
and they will be disabled in the stream sequence. To enable
these streams, please click on the Stream Setup button on
the Analyzer Operation screen.
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5.2.5.1 Status
The following descriptive status and definitions are applicable for only the stream
test and are in addition to those defined for all start-up diagnostics.
Status Description
Failed Initial Pressure Failed the Initial Pressure test.
Failed Resting Pressure Failed the Resting Pressure test.
Failed No Pressure Failed the Maximum Pressure test.
Failed Holding Pressure Failed the Holding Pressure test.
Failed Flowing Pressure Failed the Flowing Pressure test.
Failed Ending Pressure Failed the Ending Pressure test.
This will be displayed by streams waiting to be tested. The tests
Waiting
are run sequentially.
5.2.5.2 Description
These alarms are indicative of a sample pressure problem. The causes range
from a plugged frit filter to a bad GC module.
1) Perform the sample vent pressure test procedure, found in this chapter, for
the sample vent. If the test failed, proceed to the next step.
2) Perform the feed-through assembly blockage test on the sample vent (SV).
If the test fails, replace the feed-through assembly with new or refurbished
assembly.
a clean, lint free atmosphere. Because the customer does not
have the required equipment to determine which specific
module needs replaced, the final instructions are by process
of elimination, beginning with the most likely module.
The Totalflow repair department offers a range of services for
troubleshooting and repairing/replacing the non-functioning
parts. For more information regarding the repair service,
contact customer service:
3) Using the Analytical Module Assembly instructions in Chapter 4-
5.3 Troubleshooting Alarms

This section focuses on determining what has caused an alarm following normal
operation. The Totalflow NGC8200 has an extensive built-in list of alarms, some
of which are user configurable. These alarms may be grouped into three areas:
warning, fault and system fault. See Table 51 for a list of all enabled alarms. To
2101510-002 rev. AE Page 57

view all the available alarms, select Setup under Stream 1 on the Analyzer
Operation screen and select Alarm Definitions.
Additionally, component high/low concentration, component
peak not found and component RF limit exceeded alarms
are available but disabled. These alarms may be enabled by
the user, but are not included here for the purposes of
troubleshooting. Please see the PCCU32 help files for more
information regarding these.
Table 51 NGC8200 Alarms
Description Enable Type Severity

Pressure Regulator 1 Yes GT Fault
Pressure Regulator 2 Yes GT Fault
Sample Pressure Yes GT Fault
Oven Temperature Error Yes GT System Fault
No Stream Valve Selected Yes GT System Fault
Digital-Analog Bd Comm Error Yes GT System Fault
Calculation Error Yes GT Fault
Calibration Un-Normalized Total Yes GT Fault
Stream Sequence Error Yes GT Fault
Calibration CV Percent Error Yes GT Fault
RF Pct Error Yes GT Fault
Analog Bd Ambient Temp Yes GT Warning
Analog Power Supply Yes GT Warning
Low Carrier Gas Bottle (DI1) Yes LT Warning
Low Cal Gas Bottle (DI2) Yes LT Warning
GCM Chrom Process Yes GT System Fault
Bad Bead Yes GT Fault
No Pilot Valve Change Detected Yes GT Fault
Sample Flow Detect Yes GT Fault
CPU Loading Yes GT Warning
System Memory Available Yes LT Warning
Ram File Available Yes LT Warning
Flash File Available Yes LT Warning
Missing Peak-Cal Not Used Yes GT Warning
Stream Un-Normalized Total Yes GT Warning
5.3.1 Operators
GT = Greater Than
LT = Less Than
And = Including
Page 58 2101510-002 rev. AE

Or = Instead of
GE = Greater Than or Equal To
LE = Less Than or Equal To
NAND = And Not
Nor = Not Or
Plus = In addition to
Minus = Not Included or subtract from
5.3.2 Alarm Severity
Table 52 Alarm Severity
Type Definition
Indicates that an alarm exists, but that it is not critical to the operation of the unit. Use
General general when testing for some condition that may occur from time to time and want to
know when it happens.
Indicates that an alarm exists, but typically is not critical but may indicate or provide
Warning
unexpected results.
Indicates that a malfunction exists that may affect the operation of the unit and most
likely will provide unexpected results. The fault will keep any affected streams from
Fault having their data updated. However, a fault would not stop a scheduled or manually
initiated calibration from occurring, and, if the calibration corrects the alarm condition, the
alarm will be cleared.
This typically indicates that a maintenance problem exists. Analysis processing will still
occur depending on the problem; however, results will not be updated for any stream
System Fault while this condition exists. Default system faults are already defined, and, unless the
user has a situation in which he/she wants to stop all stream data from being updated,
should not use this category of alarm.
5.3.3 Pressure Regulator 1 or 2 Alarm
If the pressure regulator 1 or pressure regulator 2 alarm is in fault status, the

following procedure will step the user through the troubleshooting process. On
occasion, these instructions may detour to other procedures, and, when complete,
5.3.3.1 Description
These alarms are indicative of low or restricted carrier pressure. The causes
range from an empty or low carrier bottle, restricted pressure or to a blockage
inside the GC module.
1) If the carrier bottle regulator includes an installed low pressure switch,
investigate if the low carrier gas bottle warning is also present; otherwise,
continue to next step.
If the low carrier gas bottle warning is present, replace the carrier gas bottle;
otherwise, continue to the next step.
2) Verify the carrier gas bottle pressure is above 90 PSIG. If the pressure is
below 90 PSIG, replace the carrier gas bottle.
2101510-002 rev. AE Page 59

correct the set point to 90 PSIG.
4) Verify the column vent 1 (CV1) and 2 (CV2), sample vent (SV) and gauge
port vent (GPV) are open and unobstructed.
5) Check the sampling system for leaks and tubing restrictions. Repair the leak
or restriction, if found. Otherwise, continue to the next step.
6) Perform start-up diagnostics.
7) If the carrier pressure regulator 1 and 2 tests both pass, continue to the next
step.
8) Perform Column Vent Pressure Test procedure, found in this chapter, for
both column vent 1 and column vent 2. If either test failed, proceed to the
next step.
9) Perform Feed-through Assembly Blockage Test procedure, found in this
chapter, on column vent 1 (CV1) and column vent 2 (CV2). If the test fails,
replace the feed-through assembly with a new or refurbished assembly.
a clean, lint free atmosphere.
Because the customer does not have the required equipment
to determine which specific module needs replaced, the final
instructions are by process of elimination, beginning with the
most likely module.
10) Using the Replacing Analytical Module instructions in Chapter-4
5.3.4 Sample Pressure Alarm
If the sample pressure alarm is in fault status, the following procedure will step the
detour to other procedures, and, when complete, should return the user to these
5.3.4.1 Description
These alarms are indicative of low sample or calibration gas pressure. The causes
range from an empty or low calibration gas bottle to a blockage inside the GC
module.
Page 510 2101510-002 rev. AE

1) If the calibration gas bottle regulator includes an installed low pressure
switch, investigate if the lo bottle calibration gas warning is also present;
otherwise, continue to next step.
If the lo bottle calibration gas warning is present, replace the calibration gas
bottle; otherwise, continue to the next step.
2) Verify the calibration gas bottle pressure is above 15 PSIG. If the pressure
is below 15 PSIG, replace the calibration gas bottle. Otherwise, continue to
next step.
3) Verify the calibration gas bottle pressure regulator set point is 15 PSIG. If
not, correct the set point to 15 PSIG. Otherwise, continue to next step.
4) Verify the sample vent is open and unobstructed.
5) Perform Sample Vent Pressure Test, found in this chapter. If the test failed,
continue to the next step; otherwise, skip to step 7.
6) Perform the Feed-through Assembly Blockage Test found in this chapter, on
the sample vent (SV). If the test fails, replace the feed-through assembly.
Otherwise, continue to next step.
7) Check the sampling system for leaks and tubing restrictions. Repair the leak
or restriction, if found. Otherwise, continue to next step.
8) Perform start-up diagnostics. If the stream test fails, continue to the next
step.
9) Follow Replacing Frit Filters instructions in Chapter 4-Maintenance, verify
filters are clean and free of obstructions. If needed, replace filters.
a clean, lint free atmosphere.
Because the customer does not have the required equipment
to determine which specific module needs replaced, the final
instructions are by process of elimination, beginning with the
most likely module.
10) Using the Analytical Module Assembly instructions in Chapter 4-
5.3.5 Oven Temperature Error Alarm
If the oven temperature error alarm is in system fault status, the following
procedure will step the user through the troubleshooting process. On occasion,
these instructions may detour the user to other procedures, and, when complete,
they should return to these procedures to continue.
2101510-002 rev. AE Page 511

5.3.5.1 Description
This alarm is indicative of an issue surrounding the ability to control the oven
temperature. The causes range from an unplugged cable, to an inability to
communicate with a sensor.
1) Verify that the auxiliary heater switch on the analytical processor board
coincides with the feed-through assembly configuration. If the feed-through
assembly has an installed auxiliary heater, verify that the switch on board is
set to normal. If no auxiliary heater is installed, the switch should be set to
override.
2) Verify that the temperature sensor is plugged into the GC module.
3) Follow the Temperature Sensor Test procedure found in this chapter. If the
test fails, follow the Temperature Sensor to GC Module Assembly
Replacement instructions in Chapter 4-Maintenance.
4) Remaining options are not field repairable. Using the Analytical Module
Assembly instructions in Chapter 4-Maintenance, replace the analytical
module assembly.
The information provided for troubleshooting this alarm is only
intended to cover basic steps that can be performed in the
field. On occasion, additional troubleshooting steps may be
provided by Totalflow technical support in an effort to reduce
down time. Additionally, it may be desirable to return a
module to Totalflow for comprehensive testing and/or repair.
5.3.6 No Stream Valve Selected
If no stream valve selected alarm is in system fault status, the following procedure
will step the user through the troubleshooting process. On occasion, these
instructions may detour the user to other procedures, and, when complete, they
should return to these procedures to continue.
5.3.6.1 Description
These alarms are indicative of an attempt to run a cycle with insufficient sample
pressure. If the sample pressure is too low when diagnostics are run, it will disable
all streams but continue to try and run chroms. This can also be caused if the
digital and analytical board moves out of synchronization.
1) Check the sampling system for leaks, tubing restrictions and incorrect
pressure settings. Repair the leak or restriction, or adjust the pressure
setting, if found; otherwise, continue to next step.
2) Place the NGC in hold, allow ten minutes (approximately two cycles) to
lapse and then run a single cycle. If the alarm reappears, continue to the
next step.
3) The unit should still be in hold. Manually enable all streams.
4) Perform start-up diagnostics.
Page 512 2101510-002 rev. AE

If the stream test fails, continue to the next step.
5) Perform a warm start.

5.3.7 Digital-Analog Board Communication Error Alarm
If the digital-analog board communication error alarm is in system fault status, the
following procedure will step the user through the troubleshooting process. On
occasion, these instructions may detour the user to other procedures, and, when
complete, they should return to these procedures to continue.
5.3.7.1 Description
These alarms are indicative of a communication error between the digital board
and the analytical processor board. Verify the cable connectors are firmly and
correctly connected to both the digital and analytical processor boards.
1) In the alarm log, check the frequency of the error. If multiple errors exist,
place the unit in hold and then launch a cycle.
2) If the alarms continue to register, perform a warm start.
3) When the unit completes the start-up diagnostics without error, place the
unit in run.
4) Following 2-3 cycles, verify that no new alarms are registering.
If the alarms continue to register, call Totalflow technical support.
5.3.8 Calculation Error Alarm
If the calculation error alarm is in fault status, the following procedure will step the
detour the user to other procedures, and, when complete, they should return to
these procedures to continue.
5.3.8.1 Description
These alarms are indicative of the AGA-8 compressibility calculation not
functioning properly. Typically, this error would be caused by a gas sample being
out of specification for AGA-8 but could indicate that the components peak has
shifted.
2101510-002 rev. AE Page 513

1) Following Calibrating the NGC instructions in Chapter 3-Startup, perform a
calibration ensuring that the next mode is set to hold.
2) When the unit enters hold, select Peak Find.
3) Verify that the peaks are correctly labeled and integrated. If the peaks are
not correctly labeled and integrated, continue to the next step.
Otherwise, skip to step 5.
4) In the Peak Find screen, Run Auto PF. This process will typically require 45
minutes to complete. When the cycle is complete, repeat step 3.
5) Under Next Mode, select Run.
6) Allow the unit to run a minimum of an hour and then perform a calibration.

5.3.9 Calibration Un-Normalized Error Alarm
If the calibration un-normalized error alarm is in fault status, the following

5.3.9.1 Description
These alarms are indicative of a change to the un-normalized total of sufficient
percentage to activate the alarm. This alarm will discontinue a scheduled
calibration and will need to be disabled prior to calibrating the unit.
the next step.
2) Verify the calibration blend concentrations to calibration blend
concentrations listed on the Calibration Setup screen. If an error exists,
make corrections and send the setup when complete.
3) Under Stream Setup, Alarm Definitions, locate the calibration un-normalized
error alarm and set alarm enable to No. Send change. Repeat for any
additional streams with this alarm.
4) Following the Calibrating the NGC instructions in Chapter 3-Startup,
perform a calibration ensuring that the Next Mode is set to Hold.
5) When unit enters hold, select Peak Find.
correctly labeled and integrated, return the unit to operation; otherwise,
continue to the next step.
Page 514 2101510-002 rev. AE

7) Select Peak Find from the Analyzer Operation screen. Ensure that
Automatic is check marked and then select Run Auto PF. This procedure
will require approximately 45 minutes.
8) When the unit enters hold, verify that the peaks are correctly labeled and
integrated. If the peaks are correctly labeled and integrated, return the unit
to operation; otherwise, contact Totalflow technical support.
9) Reset the Alarm Enable to Yes. Verify that the alarm threshold is a valid
configuration. Typically, the un-normalized total should be within .50%
(between 99.5 and 100.5).
10) Return the unit to regular operation.
5.3.10 Stream Sequence Error Alarm
If the stream sequence error alarm is in fault status, the following procedure will
step the user through the troubleshooting process. On occasion, these instructions
may detour the user to other procedures, and, when complete, they should return
to these procedures to continue.
5.3.10.1 Description
These alarms are indicative of a synchronization problem following a manual data
post process in factory mode.
the next step.
2) Following Reset Procedure instructions in Chapter 4-Maintenance, perform
a warm start.
5.3.11 Calibration CV Percent Error Alarm
If the calibration CV percent error alarm is in fault status, the following procedure
These alarms are indicative of a change to the CV Percent of sufficient
2101510-002 rev. AE Page 515

the next step.
concentrations listed on the Calibration Setup screen. If the errors exist,
3) Under Stream Setup, Alarm Definitions, locate the Calibration CV Percent
Error Alarm and set Alarm Enable to No. Send the change. Repeat for any
additional streams with this alarm.
5) When the unit enters hold, select Peak Find.
correctly labeled and integrated, return the unit to operation.
configuration.
5.3.12 Calibration RF Percent Error Alarm
If the response factor (RF) percent error alarm is in fault status, the following
These alarms are indicative of a change to the response factor of sufficient
concentrations listed on the Calibration Setup screen. If the errors exist,
the next step.
3) Under Stream Setup, Alarm Definitions, locate the RF Percent Error Alarm
and set Alarm Enable to No. Send the change. Repeat for any additional
streams with this alarm.
4) When the unit enters hold, select Peak Find. Select Run Auto PF.
Page 516 2101510-002 rev. AE

correctly labeled and integrated, return the unit to operation.
6) Allow unit to cycle 3-4 times.
configuration.

5.3.13 Enclosure Temperature Alarm
If the enclosure temperature alarm is in warning status, the following procedure

These alarms are indicative of either extremely high or low temperatures inside
the enclosure. Causes could range from external temperatures being extremely
high or low, to a bad temperature sensor on the analytical board.
1) Compare the outside temperature with the temperature reading on the
Analyzer Operation screen, Enclosure Temperature. Atmospheric
temperature could be less than the enclosure temperature by as much as
20 degrees.
If the temperature differential seems reasonable, the unit may be operating
out of range. This unit is designed to operate between 0 F and 120 F.
2) If the temperature differential does not seem reasonable, the analytical
processor assembly may have a bad temperature sensor. As this alarm is
only a warning, it will not effect the operation of the unit. The user may
replace the analytical module, as needed.
2101510-002 rev. AE Page 517

5.3.14 Power Supply Alarm
If the power supply alarm is in warning status, the following procedure will step the
These alarms are indicative of input voltage either below 11 volts or above 16
volts. Causes may range from a power supply issue to a bad cable.
5.3.14.2 Instruction
1) Check the power supply to termination panel, following instructions later in
this chapter, Termination Panel Supply Voltage Test. If the test fails, restore
the power supply to proper working specifications; otherwise, continue to
the next step.
2) Following the Cable Replacement instructions in Chapter 4-Maintenance,
check the analytical processor to termination panel cable for damage. If the
cable is damaged, replace; otherwise, continue to the next step.
3) Following the Cable Replacement instructions in Chapter 4-Maintenance,
check the termination panel to digital controller cable for damage. If the
cable is damaged, replace; otherwise, contact Totalflow technical support
for additional instructions.
5.3.15 Low Carrier Gas Bottle (DI1) Alarm
If the low carrier gas bottle (DI1) alarm is in warning status, the following
These alarms are indicative of the carrier gas bottle pressure below the threshold.
1) Verify that the carrier gas bottle regulator low pressure switch threshold is
set around 90 PSIG. The alarm is switched when pressure drops below the
threshold.
2) If the threshold is above the current bottle PSIG, replace the carrier gas
bottle.
3) If the threshold is below the current bottle PSIG, verify the regulator is
functioning properly.
4) Perform the Abnormal Calibration Gas Depletion procedure, found in this
chapter. If the procedure fails to locate the problem, contact Totalflow
technical support following the procedure in the Introduction section of this
manual.
Page 518 2101510-002 rev. AE

5.3.16 Low Cal Gas Bottle (DI2) Alarm
If the lo bottle calibration gas (DI2) alarm is in warning status, the following
These alarms are indicative of the calibration gas bottle pressure below the
threshold.
1) Verify that the calibration gas bottle regulator low pressure switch threshold
is set around 15 PSIG. The alarm is switched when the pressure drops
below the threshold.
2) If the threshold is above the current bottle PSIG, replace the calibration gas
bottle.
3) If the threshold is below the current bottle PSIG, verify the regulator is
functioning properly.
4) Perform the Abnormal Calibration Gas Depletion procedure, found in this
chapter. If the procedure fails to locate the problem, contact Totalflow
technical support following the procedure in the Introduction section of this
manual.
5.3.17 GCM Processing Error Alarm
If the GCM chrom process alarm is in warning status, the following procedure will
This alarm is indicative of an error that stops the GCM application from signaling
the chrom application to process a chrom. The following internal errors could
instigate this alarm: communication response error, polling error, sequence error
and data error.
1) In the alarm log, check the frequency of the error. If multiple errors exist,
place the unit in hold and then launch a cycle.
2) If the alarms continue to register, perform a warm start.
3) When the unit completes the start-up diagnostics without error, place the
unit in run.
4) Following 2-3 cycles, verify that no new alarms are registering.
If alarms continue to register, call Totalflow technical support.
2101510-002 rev. AE Page 519

5.3.18 Bad Bead Alarm
If the bad bead alarm is in fault status, the following procedure will step the user
through the troubleshooting process. On occasion, these instructions may detour
the user to other procedures, and when complete, they should return to these
These alarms are indicative of problem with the GC module.
1) Following the GC Module Replacement instructions in Chapter 4-
Maintenance, replace the GC module.
5.3.19 No Pilot Valve Change Detected Alarm
If no pilot valve change detected alarm is in warning status, the following

These alarms are indicative of the pressure regulator problem on the manifold.
During backflush, a valve is changed, but no disturbance is registered.
1) Verify the carrier gas bottle pressure is above 90 PSIG. If the pressure is
below 90 PSIG, replace the carrier gas bottle.
correct the set point to 90 PSIG.
3) Following the Manifold Replacement instructions in Chapter 4-Maintenance,
replace the manifold.
5.3.20 Sample Flow Detection Alarm
If the sample flow detection alarm is in fault status, the following procedure will
These alarms are indicative of a pressure issue such as a blocked vent tube, too
short bleed cycle, stream test is in auto, etc.
1) Inspect the vent tubes for blockage, including crimps in tubing, dirt or debris.
Page 520 2101510-002 rev. AE

2) Following the instructions later in this chapter, perform the sample pressure
test.
3) Verify the sample bleed time is set greater than one second.
4) Following the GC Module Replacement instructions in Chapter 4-
Maintenance, replace the GC module.
5.3.21 CPU Loading Alarm
If the CPU loading alarm is in warning status, the following procedure will step the
These alarms are indicative of the processor being overloaded. An occasional
spike in processor loading is to be expected. Multiple occurrences are not field
repairable.
1) View the alarm history for multiple occurrences. If an occasional warning is
registered, this is not a problem.
2) If multiple alarm occurrences exist, contact Totalflow technical support for
additional help.
5.3.22 System Memory Available Alarm
If the system memory available alarm is in warning status, the following procedure
These alarms are indicative of the task memory resource getting full. The
recommended files size for the task memory is 1 to 2 MB. This alarm may be
received after adding additional applications.
2) View the resources from the PCCU Entry screen to check the available
memory. If applicable, the available memory could be increased
incrementally.
Please note that when increasing the available memory, the

available RAM file space is reduced. Caution should be used!
3) Following the Reset Procedure instructions in Chapter 4-Maintenance,

warm start the unit to defrag the system memory.
4) Reducing the number of instantiated applications may be required. Contact
Totalflow technical support for assistance.
2101510-002 rev. AE Page 521

5.3.23 RAM File Available Alarm
If the RAM file available alarm is in warning status, the following procedure will
These alarms are indicative of the TFData file resource becoming full. The
recommended files size for TFData is 2 to 3 MB. This alarm may be received after
changing the log period frequency, adding applications or setting up additional
trend files.
2) View the resources from the PCCU Entry screen to check the available
RAM file space. If applicable, the RAM file space could be increased
incrementally.
Please note that when increasing the RAM file space, the
available memory file space is reduced. Caution should be
used!
3) Following the Reset Procedure instructions in Chapter 4-Maintenance,
warm start the unit to defrag the system memory.
4) Reducing the number of instantiated applications, trend files or lengthening
the log periods may be required. Contact Totalflow technical support for
assistance.
5.3.24 FLASH File Available Alarm
If the FLASH file available alarm is in warning status, the following procedure will
These alarms are indicative of a shortage of file space in the 32 MB FLASH.
Typically, this space is not user accessible; however, instantiating too many
applications may cause an alarm.
2) Please contact Totalflow technical support for assistance.
5.3.25 Missing Peak-Calibration Not Used
If the missing peak-calibration not used is in warning status, the following

Page 522 2101510-002 rev. AE

These alarms are indicative of a missing peak during a calibration cycle and
calibration will not be used.
1) Verify the calibration blend concentrations to the calibration blend
concentrations listed on the Calibration Setup screen. If errors exist, make
corrections and send the setup when complete.
the next step.
3) When the unit enters hold, select Peak Find from the Analyzer Operation
screen. Ensure that Automatic is check marked and then select Run Auto
PF. This procedure will require approximately 45 minutes.
4) Verify that peaks are correctly labeled and integrated. Refer to Figure 35
and Figure 36 for comparison. On chrom 1, NC5 peak should elute around
160 seconds. On chrom 2, C2 peak should elute at approximately 220
seconds. If peaks are correctly labeled and integrated, return the unit to
operation, and continue to the next step; otherwise, contact Totalflow
technical support.
5) Allow the unit to cycle 3-4 times.
7) When the unit enters hold, verify that peaks are correctly labeled and
integrated. If peaks are correctly labeled and integrated, return the unit to
operation.
8) If peaks are not correctly labeled and integrated, contact Totalflow technical
support for assistance.
5.3.26 Stream Un-Normalized Total
If the stream un-normalized total is in warning status (default), the following

procedure will step the user through the troubleshooting process. If the severity of
the alarm is set to fault, the new stream data is not allowed to update. On
occasion, these instructions may detour the user to other procedures, and, when
complete, they should return to these procedures to continue.
These alarms are indicative of a change to the process stream un-normalized total
of the sufficient percentage to activate the alarm.
1) Verify that the alarm threshold is a valid configuration. Typically, the
unnormalized total should be within 6.50% (between 99.5 and 100.5).
2101510-002 rev. AE Page 523

2) Verify the calibration blend concentrations to the calibration blend
concentrations listed on the Calibration Setup screen. If errors exist, make
corrections and send the setup when complete.
the next step.
4) When the unit enters hold, select Peak Find. Select Run Auto PF. Ensure
that Automatic is check marked and then select Run Auto PF. This
procedure will require approximately 45 minutes.
5) Verify that peaks are correctly labeled and integrated. If peaks are correctly
labeled and integrated, return the unit to operation; otherwise, continue to
the next step.
6) Allow unit to cycle 3-4 times.
7) Follow the Calibrating the NGC instructions in Chapter 3-Startup, perform a
calibration.
5.4 Alarm Troubleshooting Tests
5.4.1 Sample Vent Pressure Test
1) Attach flowmeter to the sample valve.
2) From the Analyzer Operation screen, click on Diagnostics.
3) Select the Manual Operation tab.
4) Under Manual Control, open the sample shutoff valve.
5) When opened, the SV should measure a spike to 15 sccm. Close the valve
when done reading.
6) If the SV does not spike to 15 sccm, the test has failed.
7) Return to troubleshooting instructions.
5.4.2 Column Vent Pressure Test
1) Attach flowmeter to CV1.
3) Select the Manual Operation tab.
4) Under Manual Control, open the stream 1 valve.
5) When opened, the CV1 should measure between 312 sccm. Close the
valve when done reading.
6) If the CV1 measures within this range, continue to the next step. If CV1
does not measure within the range, the test has failed. Return to
troubleshooting alarm instructions.
7) Attach flowmeter to CV2.
8) Open the stream 1 valve.
9) When opened, CV2 should measure between 312 sccm. Close the valve
when done reading.
Page 524 2101510-002 rev. AE

10) If CV2 does not measure within this range, the test has failed. Return to
troubleshooting alarm instructions.
5.4.3 Sample Pressure Test
1) Place unit in Hold.
3) Select the Manual Operation tab and select Monitor.
4) Read the sample pressure from the current reading.
5) Under Manual Control, open stream 1 valve or stream reflecting alarm.
6) Under Manual Control, close the sample shutoff valve.
7) The sample pressure reading under Current should increase.
8) Under Manual Control, open the sample shutoff valve.
9) The sample pressure reading under Current should decrease rapidly.
10) If the pressure decreases slowly, close the sample shutoff valve and return
to the troubleshooting alarm instructions. The test has failed.
5.4.4 Feed-through Assembly Blockage Test

1) Remove the feed-through assembly from the NGC following Feed-through
Assembly instructions in Chapter 4-Maintenance.
2) If testing from the pressure regulator 1 or 2 alarms, continue to steps 3 and
4.
If testing from the stream test in the start-up diagnostics or from the sample
pressure alarm, skip to step 5.
3) Attach the pressure source to CV1 and activate. If the flow through
assembly is impeded, the test has failed. Return to troubleshooting alarm
instructions; otherwise, continue to next step.
4) Attach the pressure source to CV2 and activate. If the flow through
assembly is impeded, the test has failed. Return to the column vent
pressure test.
5) Attach the pressure source to SV and activate. If the flow through assembly
is impeded, the test has failed. Return to the troubleshooting alarm
instructions.
5.4.5 Temperature Sensor Test
1) Unplug the sensor from the GC module.
2) Connect the digital multimeter (DMM), set to read resistance, positive lead
to pin 1 and negative lead to pin 2.
3) The meter should indicate a resistance reading between approximately 10 K
ohms and 1 M ohms. The resistance value is dependent on the temperature
of the gas chromatograph oven and ambient temperature; therefore, any
reading in this range should indicate a functioning temperature sensor.
2101510-002 rev. AE Page 525

5.4.6 Abnormal Calibration Gas Depletion
5.4.6.1 Description
If the calibration (and/or carrier) gas has depleted significantly sooner than
expected, there may one or more issues.
1) If the NGC has been running normally but consuming too much calibration
(and/or carrier) gas, carefully leak test the gas bottle regulator, tubing and
connections to the NGC.
2) If the unit is new start-up installation, check and tighten the analytical
module mounting bolt. The module may have been loosened due to
vibration during shipping.
3) If the unit has been disassembled recently, re-check and tighten all
assemblies including the analytical module mounting bolt.
4) If the NGC has been powered down for any significant length of time, the
calibration (also carrier and sample) gas should be shut off. Some valves
may be left in an open or partially open state allowing gas to continue
flowing.
5.5 Power Troubleshooting
5.5.1 Overview
This section focuses on determining what has caused the NGC to lose power.
Generally, the loss of power can be attributed to only the power supply system.
However, if the power supply system is used for powering a transceiver, or other
peripheral equipment, a problem with that equipment may drain the battery and
cause the NGC to lose power. Notice that the power troubleshooting flowchart
(see Figure 52) takes the user through several tests, but also directs them to the
communication troubleshooting flowchart located further in this chapter.
Page 526 2101510-002 rev. AE

START
Go To
Charger Circuit YES Batteries NO
Test Dead?
Go To
Power Supply
Voltage Test
RETURN
YES
END Power Issue
Located?
NO
Perform Tests
Sequentially
Go To Go To Go To Go To
Equipment NGC Module Solar Panel COMM
Isolation Test Isolation Testing Troubleshooting Troublelshooting
Test Chart
YES NO
Power Issue Return to Test
END
Located? Sequence
Figure 52 Power Troubleshooting Flowchart
2101510-002 rev. AE Page 527

5.5.2 Power Supply Voltage Test
This test assumes a power supply is in good working order
and has previously been tested and qualified to power an
NGC. If the power supply is under suspicion, it is
recommended that it be replaced with a known good power
supply before conducting these tests.
1) Check that the power supply voltage setting, the power supply current rating
and the cables used for the installation meet the recommended
requirements (see System Specifications in Chapter 1).
If this is a new installation and the external equipment is being powered
from the NGC termination panel, call Totalflow technical support for help in
evaluating the cable and power supply installation requirements.
Correct and retest as necessary.
2) Check for a poor cable connection in the cable between the NGC and the
power source. Verify all field wiring screw terminals are tight.
3) Verify that there are no other devices that may drop an excessive voltage
across them in the power supply circuit (to the NGC) like a fuse, diode or a
barrier device, etc.
4) Disconnect the power supply cable at the NGC termination panel J1.
5) Measure the power supply cable voltage at the connector and compare with
the table recommendations (see Table 14 and Table 15).
If the power supply voltage does not meet recommendations, check the
cabling and other loads on the power supply. Also check the power supply
output voltage setting.
6) Reconnect the power supply cable to the NGC termination panel J1.
5.5.3 Equipment Isolation Test
This test isolates the peripheral equipment from the equation to verify that
excessive current is not being drawn from the power source, thus reducing the
amount of power supplied to the NGC.
This procedure assumes that the previous power supply voltage test was
performed and that no errors were found.
1) While the NGC is operating, verify that the voltage at the NGC termination
panel is between 11.5 VDC-16 VDC (for 12 VDC systems) or 22 VDC to 28
VDC (for 24 VDC systems).
Page 528 2101510-002 rev. AE

The NGC uses pulse width modulation technology to drive its
heaters and valves. Due to this feature, a DMM may not show
the voltage present at the NGC termination panel accurately.
However, in no case, even under load, should the DMM
indicate a voltage less than 11.5 VDC (or 22 VDC for 24 VDC
system) if the proper cables are used. It may be necessary to
have a digital volt meter capable of capturing "fast transients"
(less than 1 ms in duration).
For example: While using a DMM with fast transient capture
capability, set the DMM to "capture" the minimum voltage
(sometimes this is a min/max measurement) using its fast
transient capability and then let it monitor the NGC while
operating for a few minutes. This should provide a good
indication of the minimum voltage appearing at the NGC
terminals.
2) Is the voltage within limits? If no, continue to the next step. If yes, no
physical problem is found.
3) Is the external equipment, such as a radio or other device, being powered
from the NGC termination panel? If no, return to Figure 52 and continue
the test sequence. If yes, continue to the next step.
4) Disconnect the peripheral equipment from the NGC.
5) While the NGC is operating, verify that the voltage at the NGC termination
panel is between 11.5 VDC-16 VDC (for 12 VDC systems) or 22 VDC to 28
VDC (for 24 VDC systems).
6) Is the voltage within limits? If no, return to Figure 52 and continue the test
sequence. If yes, the external equipment is drawing excessive current.
Check the equipment and related wiring. Correct and retest, if necessary.
5.5.4 NGC Module Isolation Test
This test isolates the NGC modules to pinpoint equipment failure.

This procedure assumes that the previous power supply voltage test and
equipment isolation test was performed and that no errors were found.
1) With power still supplied to the termination panel J1 connector, disconnect
the power supply cable at the termination panel.
2) Using instructions in Chapter 4-Digital Controller Assembly Mounting
Bracket, remove the digital controller and disconnect the termination panel
to the digital controller cable.
3) Using instructions in Chapter 4-Replacing Analytical Module, remove the
analytical module.
4) With power still disconnected from the NGC, measure the voltage at the J1
connector screw terminals. Record the value as power supply voltage (open
circuit).
5) Reconnect the power supply cable at the NGC termination panel J1.
2101510-002 rev. AE Page 529

6) Measure voltage at the termination panel J1 connector screw terminals.
Voltage should be within 0.1 VDC of the power supply voltage (open circuit).
i.e., only 0.1 VDC drop max. between the PS and the NGC.
7) If the voltage drop is greater than 0.1V, replace the termination panel using
instructions in Chapter 4-Replacing Termination Panel and return to step 6.
If the voltage drop is again greater than 0.1V, call Totalflow technical
support, following the instructions in the Introduction to this manual, Getting
Help.
If the drop is less than 0.1V, check the termination panel to the analytical
processor cable for pinched or exposed insulation. Also, check the feed-
through auxiliary heater cable for similar damage.
8) Was the damaged cable found? If yes, replace the appropriate cable using
instructions in chapter 4.
If no, use instructions in Chapter 4- Replacing Analytical Module, and
replace the module. Skip to step 10.
9) Reinstall the analytical module.
10) Reinstall the digital controller assembly.
11) If disconnected during a procedure, reconnect the J1 power supply
connector to the termination panel. It may require 10-60 seconds for the
processors in the NGC to fully boot and for the NGC to start drawing normal
to full power. However, under normal operation, the NGC should never, at
anytime, draw current beyond its rated values.
12) Return to the equipment isolation test.
5.5.5 Charger Circuit Test
If the system setup includes a battery pack, solar panel or AC charger/power

supply connected to the optional equipment enclosure, and the units battery is not
staying charged, the user will need to test the battery pack, AC charger/power
supply or the solar panel.
The following instructions contain the steps required to perform the circuit testing.
5.5.5.1 Things to Consider

The following list points to other troubleshooting procedures that the user may
want to consider as well:
Solar Panel Troubleshooting Test
AC Charger/Power Supply Troubleshooting Test
1) Begin by disconnecting power from the AC charger/power supply, located in
the optional enclosure.
2) Replace the battery with a known good battery using the Battery Pack
Replacement procedure located in Chapter 4-Maintenance.
3) Reconnect the power to the charger/supply. If the battery pack is charged
through an AC charger, skip to step 5; otherwise, continue to step 4.
4) Measure the solar panel charging voltage at the charger regulator using a
DMM connecting the (+) and (-) leads to the (+) and (-) solar panel wires.
Page 530 2101510-002 rev. AE

Loaded voltage should be greater than or equal to the specification listed in
Table 53. If the voltage is within range, the battery was bad.
If the loaded voltage is not above the minimum, perform the solar panel
troubleshooting test found later in this chapter.
5) If the unit uses an AC charger, perform the AC charger/power supply
troubleshooting test found later in this chapter.
6) If all other testing to this point has not located the error, return to Figure 52
power troubleshooting flowchart and continue.
Table 53 Specifications for Solar Panels
Panel Max Volts @PMax Open Circuit Load Resistance Loaded Voltage
50 54W 17.4V 21.7V 5 100W 1618 VDC
85 87W 17.4V 21.7V 5 100W 1618 VDC
5.5.6 Solar Panel Troubleshooting Test
If the system setup includes a solar panel connected to the optional equipment
enclosure, and it is not supplying the required voltage and current to the NGC unit,
the user may need to test the solar panel.
The following instructions contain the steps required to do so.
5.5.6.1 Things to Consider

The following list points to other troubleshooting procedures that the user may
want to consider as well:
Power Consumption Test (Remote Equipment)
AC Charger/Power Supply Troubleshooting Test
5.5.6.2 Required Equipment

Digital Multimeter with 0-20 VDC range.
Required resistors for testing specific panels listed in Table 53.
In continuous low sun light conditions, the unit may not supply
the required voltage. The solar panel should be positioned so
it receives the most sunlight. Do not place it in a shaded area.
1) Measure the solar panel voltage at the controller assembly using a DMM
connecting the (+) and (-) leads to the (+) and (-) solar panel wires. The
loaded voltage should be greater than or equal to the specifications listed in
Table 53. If the solar panel is not above the minimum, replace the solar
panel, and continue to step 2.
2) Check the solar panel angle and direction. In the northern hemisphere, the
panel should face due south and in the southern hemisphere, due north.
3) Check the solar panel for any physical damage or obstructions to sunlight.
Sunlight obstruction prevents the solar panel from receiving enough sunlight
to charge the installed battery pack. Clear any debris from the cell face of
the panel.
2101510-002 rev. AE Page 531

4) Check the solar panel wiring to be certain it is correctly connected to the
associated termination pins located in the enclosure (see Figure 53).
5) Disconnect the solar panel from the field device.
6) Set the DMM range to read over 20 VDC.
7) Determine if the open circuit voltage is greater than or equal to the
specifications listed in Table 53 by clipping the positive lead of the DMM to
the positive wire and clipping the negative lead of the DMM to the negative
wire. If the solar panel is not above the minimum, continue to the next step.
8) Using the selected resistor from Table 53 for the solar panel wattage,
attach the selected resistor between the two solar panel wires.
Refer to Manufacturers Wiring
Diagrams for Solar Panel connectivity
Solar Charger
Temp
Sensor
Load
Charging Disconnect
Solar Panel Solar Panel

Solar Battery Load
4
+
3
-
2
+
1
-
6
+
5
- PS1
SS-20L-24V
- + - +
(+) LOAD (+) WHT

BATT (+) RED
Fuse Block 2 2 2 1 1
10Amp
TB1, Batt 1 15Amp
TB5, Spare 1Amp
TB4, Spare 1Amp
5Amp
TB2, Load
TB3, NGC
2 2
1 1
Spares
(+) BATT (+) RED

BATT (-) BLK
To NGC
BATT (-) BLK
(-) Load (-) BLK
Jumper (BLK)
J1 Buss Bar
1 4
To Battery
Cable P1
(-)
Figure 53 Solar Panel Wiring Instructions
9) Clip the positive lead of the DMM to the one side of the test resistor.
10) Clip the negative lead of the DMM to the other side of the test resistor.
11) Determine if the loaded voltage is greater than or equal to the specifications
listed in Table 53. If the solar panel is not above the minimum, replace the
solar panel and return to step 3.
5.5.7 AC Charger/Power Supply Troubleshooting Test
If the system setup includes an AC charger/power supply connected to the

optional equipment enclosure, and is not supplying the required voltage to the
Page 532 2101510-002 rev. AE

NGC unit, the user may need to test the AC charger/power supply. The following
instructions contain the steps required to do so.
1) Check the input AC voltage to the enclosure power supply. Be certain the
primary AC voltage is correct.
2) If the primary input AC voltage level is correct, and there is no DC output
from the power supply, replace the F1 charger fuse (see Figure 54).
3) If the fuse is not faulty or there is no charger DC output voltage after
replacing the fuse, replace the AC charger/power supply.
DIGITAL I/O POWER
J2 J1 Enclosure
(+) (-)
(+) (-) (+) (-) (+) (-) (+) (-) PWR IN
1 2 1 2
INPUTS OUTPUTS (-)
5VDC PWR
D2
(+)
J7
TERM J9 TERM J11

1 3 1 3
NO TERM NO TERM
13 14 DC
OK
++ - -
SERIAL PORT 1 SERIAL PORT 2 Output DC 12V 10A
J3 J10
J8 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 PHOENIX
CONTACT
ETHERNET SECURITY
J5 J6 D12 D11 D13 ENABLED RESET
DC OK
D3 D4 S1
USB HOST LINK STAT 1 2
USB CLIENT LAN STATUS Adjust
11.5-18V
Input
NGC Termination AC 100-240V
Board L N
100/120 VAC
Figure 54 AC Charger/Power Supply Wiring
5.6 Troubleshooting Communications

These troubleshooting procedures are applicable to an NGC8200 with an installed
radio in the optional equipment enclosure. Use Figure 55 as an aid for
troubleshooting communication problems. The three basic types of radio
communications that can be used between the NGC and a radio receiver are:
RS-232 Communications (see Table 54 for pin Configurations)
RS-485 Communications (see Table 56 for pin Configurations)
RS-422 Communications (available, but not detailed)
The radio/modem may be powered one of two ways: always on or switched. The
specific system set up will determine what steps are needed to power the
radio/modem.
When switching the power to a radio with inhibit (SLEEP) mode, the serial port 1
or 2 switched power line will go to the radios inhibit (SLEEP) mode input. Power
out will go to the radios power input.
2101510-002 rev. AE Page 533

5.6.1 Communication
Troubleshooting the communications for this unit requires that equipment in two
areas be tested: the NGC Comm Ports and the external Communication device.
This is discussed in more detail in the Communications Overview section.
Other communication troubleshooting information is shared in the following
categories:
RS232 Communications
5.6.2 Setting Up Communication
After the installation of the communication equipment and before placing the
communication system into operation, the user should note the following:
Verify field wiring terminations on the NGC termination panel.
Verify field wiring from the NGC unit to the termination strip inside the
enclosure.
Verify the field wiring from the termination strip to the radio.
Check the NGC identifier (ID). Log the ID for future reference.
Log the NGC access security code, baud rate, listen cycle, protocol and
interface for future reference.
Page 534 2101510-002 rev. AE

START
Verify unit
ID#, Security
Code and
Protocol are
Correct.
Verify jumper
and terminal &
pin wiring are
correct.
NO
Does Unit Transceiver
YES NO Transceiver Investigate
Respond to Host Supply voltage
END Supply voltage Transceiver
Comm Request? Test
within Specs? Issues
YES
12V
Investigate Communication
YES Voltage supply
Power Supply Supply Voltage
from NGC unit Test
Issues
=10.5 VDC?
Figure 5-1
NO
Substitute
YES Unit Respond to Communication
Host Comm Test Cable
Request?
NO
Contact
Is NO Is NO
Totalflow
Communication Communication Technical
RS-232? RS-485? Support
YES YES
RS-232 RS-485
Communication Communication
Test Test
Does Unit
Respond?
YES
NO
Transceiver
NO
Comm Check
Test Passed?
YES
Figure 55 Communication Troubleshooting Flowchart
2101510-002 rev. AE Page 535

The following helpful hints aid the user after the
communication equipment has been installed and setup:
When the communication equipment is powered/switched
on, the NGC displays the communication icon after it
recognizes the NGC ID and is responding.
Check the baud rate of the NGC transmission and the listen
time settings. The baud rate and time settings can be
changed by entering the Station Setup screen from the
Analyzer Operation screen. Default settings are 1200 baud
and the listening time is four seconds with the
communications interface turned off.
The minimum power required for operating the remote
communications is 11.9 VDC (default) or as set by user.
Should the power fall below this level, remote
communications will be terminated.
Test the remote communications using RS-232
troubleshooting cable. Use the RS-232 to RS-485
communication converter in conjunction with the RS-232
troubleshooting cable to test the RS-485 remote
communications.
5.6.3 Transceiver Supply Voltage Test
Using the wiring information and guidelines supplied by the transceiver

manufacturer, verify that the transceiver is receiving the manufacturers suggested
voltage. If the unit is receiving sufficient voltage, continue to the optional
equipment enclosure wiring voltage test.
If the transceiver is not receiving sufficient voltage,
investigate the power supply issues. These may involve
wiring irregularities at the AC charger/power supply,
XFC/XRC board or at the power relay if using the relay for
switching power to the radio.
5.6.4 12 VDC Communication Supply Voltage Test
If the transceiver does not feature a sleep mode and power is supplied through an
optional relay, begin with Step 1 -Relay Supply Voltage Test.
If the transceiver features a sleep mode, or is continuously powered, begin with
step 2.
1) If the transceiver does not feature a sleep mode and receives power
through an optional relay, activate serial port 1 or 2 switched power out (pin
3) and, using a digital multimeter (DMM) set to volts DC, measure the
voltage at the relay between relay coil terminals.
If the voltage reads the same as the supplied voltage (12 VDC) and the
transceiver is still not receiving power, the relay may be incorrectly wired
(use normally open contacts), or the relay may be bad.
If the relay is not receiving power, continue to step 2.
Page 536 2101510-002 rev. AE

2) If the transceiver features a sleep mode or is continuously powered, using a
digital multimeter (DMM) set to volts DC, measure the voltage at each
power supply wiring junction. Verify the wiring is firmly connected and
measure the voltage between:
Power (+) and Ground (-).
The voltage should be greater than or equal to 11.9 VDC for this unit. If the
voltage is less than 11.9, return to the test sequence outlined in the power
troubleshooting flowchart (see Figure 52).
5.6.5 Transceiver Check
1) If available, use a wattmeter to check the transceiver output power. Refer to
the manufacturers documentation for measuring instructions.
2) If available, use two (2) hand-held transceivers, and verify the
communication path between the master and remote sites. Voice activated
interface can be used, if available.
3) Verify that the transceiver is set to the correct frequency. Refer to the
manufacturers documentation for checking frequency instructions.
4) If a directional antenna is used, verify the orientation to the antenna to the
master site.
If a communication problem still exists, and the unit has
passed the transceiver check test, contact Totalflow
customer service for additional help.
5.6.6 RS-232 Communication Test
The following RS-232 serial communication test procedure is directed from Figure
55 and will assist the user in what may be the possible cause for the indicated
error message.
Before performing this test, please verify that the field wiring is correct (see Table
54).
Table 54 RS-232 Field Wiring on NGC Termination Panel
Description Description
PIN Jack 8Port 1 Jack 10Port 2
1 Power Out Power Out
2 Ground Ground
3 Switched Power Out Switched Power Out
4 Operate Operate
5 Not Used Not Used
6 Request to Send Request to Send
7 Transmit Data Transmit Data
8 Receive Data Receive Data
9 Clear to Send Clear to Send
2101510-002 rev. AE Page 537

When troubleshooting RS-232 mode, verify the termination
settings of the serial port 1 J9 and serial port 2 J11 on the
termination panel have pins 2 and 3 jumpered.
Voltage on the following steps may be hard to see using a

digital multimeter. If available, an oscilloscope will provide a
more accurate reading. To verify, the host software must be
continuously polling the NGC.
Generally speaking, these tests performed on the terminal
board will only verify incorrect or damaged wiring. If all
previous testing passed and all wiring, jack and terminations
have been verified as correct, the board will need to be
replaced. Contact Totalflow customer service. See Getting
Help in the introduction of this manual for instructions.
1) Using an oscilloscope, measure the receiving data voltage on the
termination panel J8 or J10 between:
Port 1, J8pin 2 (Ground) and pin 8 (Receive Data) or
Port 2, J10pin 2 (Ground) and pin 8 (Receive Data).
When the unit is receiving data from the host, the voltage should vary
between -5 VDC and +5 VDC. This would indicate that the unit is receiving
data; continue to step 2. If the unit is not receiving data, investigate the
wiring issues (see Table 54).
2) Using an oscilloscope, measure the request to send voltage on the
termination panel J8 or J10 between:
Port 1, J8pin 2 (Ground) and pin 6 (Request to Send) or
Port 2, J10pin 2 (Ground) and pin 6 (Request to Send).
When the unit is communicating with the host, the voltage should be +5
VDC and remain +5 VDC until the XFC transmit stops. This would indicate
that the unit is transmitting data; continue to step 3. If the unit is not
receiving data, investigate the wiring issues (see Table 54).
3) Using an oscilloscope, measure the transmit data voltage on the termination
panel J8 or J10 between:
Port 1, J8pin 2 (Ground) and pin 7 (Transmit Data) or
Port 2, J10pin 2 (Ground) and pin 7 (Transmit Data).
When the unit is transmitting to the host, the voltage should vary between -5
VDC and +5 VDC. This would indicate that the unit is transmitting data. If
the unit is still not responding, continue to the next test as directed in Figure
55.
5.6.7 RS-485 Communications
The following RS-485 serial communication test procedure is directed from Figure
55 and will assist the user in what may be the possible cause for the indicated
error message.
Page 538 2101510-002 rev. AE

When troubleshooting RS-485 mode, verify the termination
settings of port 1 J9 and port 2 J11 on the termination panel
are correctly jumpered (see Table 55).
Table 55 RS-485 Terminations
Serial Comm Port 1 2

Jumper J9 J11
First or Intermediate Unit pins 23 pins 23
Last or Only Unit pins 12 pins 12
5.6.8 RS-485 Communication Test
Before performing this test on the termination panel located inside the rear end
cap, please verify that the wiring is correct (see Table 56).
Table 56 RS-485 Field Wiring on NGC Termination Panel
Description Description
PIN J8Port 1 J10Port 2
1 Power Power
2 Ground Ground
3 Switched Power Out Switched Power Out
4 Operate Operate
5 Remote Request to Send Remote Request to Send
6 Transmit Bus (+) Transmit Bus (+)
7 Transmit Bus (-) Transmit Bus (-)
8 Receive Bus (+) (RS-422) Receive Bus (+) (RS-422)
9 Receive Bus (-) (RS-422) Receive Bus (-) (RS-422)
Voltage on the following steps may be hard to see using a

digital multimeter. If available, an oscilloscope will provide a
more accurate reading. To verify, the host software must be
continuously polling the meter.
Generally speaking, these tests performed on the termination
panel will only verify incorrect or damaged wiring. If all
previous testing passed and all wiring, jack and terminations
have been verified correct, the termination panel may need to
be replaced, but does not typically fail. Contact Totalflow
customer service. See Getting Help in the introduction of this
manual for instructions.
2101510-002 rev. AE Page 539

1) Using an oscilloscope, measure the line driver voltage on the termination
panel J8 or J10 between:
Port 1, J8pin 7 (BUS-) and pin 6 (BUS+) or
Port 2, J10pin 7 (BUS-) and pin 6 (BUS+).
When the unit is receiving data from the host, the voltage should vary
between +5 VDC and 0 VDC. This would indicate that the unit is receiving
data.
2) Using an oscilloscope, measure the remote request to send voltage on the
termination panel J8 or J10:
Port 1, J8pin 2 (Ground) and pin 5 (RRTS)
Port 2, J10pin 2 (Ground) and pin 5 (RRTS)
When the unit is transmitting data, the voltage should vary between +5 VDC
and 0 VDC. This would indicate that the RRTS is working correctly.
3) If any inaccuracy exists, investigate the wiring errors or damaged wires.
If a communication problem still exists and the unit has
passed the tests in steps 1 and 2, additional testing will be
required.
Page 540 2101510-002 rev. AE

APPENDIX A MODBUS REGISTERS
Modbus Reg #
Input Reg Description
32-bit 16-bit
Component Index for Stream
3001 3001 51.200.0 Component Table #1 Component Index #1(C3)
3002 3002 51.200.1 Component Table #1 Component Index #2(IC4)
3003 3003 51.200.2 Component Table #1 Component Index #3(NC4)
3004 3004 51.200.3 Component Table #1 Component Index #4(Neo C5)
3005 3005 51.200.4 Component Table #1 Component Index #5(IC5)
3006 3006 51.200.5 Component Table #1 Component Index #6(NC5)
3007 3007 51.200.6 Component Table #1 Component Index #7(C6+)
3008 3008 51.200.7 Component Table #1 Component Index #8(N2)
3010 3010 51.200.9 Component Table #1 Component Index #10(CO2)
3012 3012 51.200.11 Component Table #1 Component Index #12(C6s)
3016 3016 51.200.15 Component Table #1 Component Index #16(Spare)
3017 3017 51.200.0 Component Table #2 Component Index #1

3033 3033 51.201.1 Analysis Time (in1/30ths of 1 second) (N/A)
3034 3034 51.201.0 Current Stream Number(15.0.28)
3035 3035 51.201.1 Mask of streams associated with Component Table 41 (N/A)
3036 3036 51.201.3 Current Month (1-12) (15.1.8)
2101510-002 rev. AE Page A1

Modbus Reg #
32-bit 16-bit
3037 3037 51.201.4 Current Day (1-31) (15.1.9)
3038 3038 51.201.5 Current Year (0-99) (15.1.10)
3039 3039 51.201.6 Current Hour (0-24) (15.1.11)
3040 3040 51.201.7 Current Minutes (0-59) (15.1.12)
3041 3041 51.201.8 Cycle Start Month (1-12) (15.1.13)
3042 3042 51.201.9 Cycle Start Day (1-31) (15.1.14)
3043 3043 51.201.10 Cycle Start Year (0-99) (15.1.15)
3044 3044 51.201.11 Cycle Start Hour (0-24) (15.1.16)
3045 3045 51.201.12 Cycle Start Minutes (0-59) (15.1.17)
3046 3046 51.201.42 Bit Flags Transmitter
3047 3047 51.201.43 Bit Flags Transmitter
3048 3048 51.201.1 Bit Flags Stream #1 Low (N/A)
3049 3049 51.201.1 Bit Flags Stream #1 High (N/A)
Int16 for Stream

3058 3058 51.201.2 New Data Flag(15.1.7)
3059 3059 51.201.13 Cal/Analysis Flag(15.1.18)
3060 3060 51.201.32 Read the Current State (19.1.0)

3061 3061 51.201.33 Read the Next State (19.1.0)
3062 3062 51.201.1 Auto Calibration During Start-up (N/A)
3063 3063 51.201.22 Alternate Purge Cycles (15.0.24)
3064 3064 51.201.23 Alternate Calibration Cycles (15.0.19)
3065 3065 51.201.24 Number of Purge Cycles (15.0.23)
3066 3066 51.201.25 Number of Calibration Cycles (15.0.18)
3067 3067 51.201.1 Low Carrier Mode (N/A)
3068 3068 51.201.1 Low Power Mode (N/A)
3069 3069 51.201.1 Pre-Purge Selection (Future)
3070 3070 51.201.1 Normal Status (N/A)
3071 3071 51.201.1 Fault Status (N/A)
3072 3072 51.201.26 Carrier Bottle Low (DI1) (11.0.0)
3073 3073 51.201.27 Calibration Bottle Low (DI2) (11.0
Page A2 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
3074 3074 51.201.1 Manual Update Response Factors (N/A)
3075 3075 51.201.1 Auto Update Response Factors (N/A)
3076 3076 51.201.1 Disable Stream Switching (N/A)
3077 3077 51.201.1 Transmitter Current Warning (N/A)
3078 3078 51.201.1 Transmitter Current Fault (N/A)
3079 3079 51.201.1 Transmitter Initial Warning (N/A)
3080 3080 51.201.1 Transmitter Initial Fault (N/A)
3081 3081 51.201.18 Stream #1 Current Warning (15.128.1)
3085 3085 51.201.14 Stream #1 Current Fault (15.128.0)
3089 3089 51.201.38 Stream #1 Initial Warning (15.128.3)
3093 3093 51.201.34 Stream #1 Initial Fault (15.128.2)
3097 3097 51.201.28 Stream #1 Skip Flag (19.0.7)
3098 3098 51.201.29 Stream #2 Skip Flag (19.0.8)
3099 3099 51.201.30 Stream #3 Skip Flag (19.0.9)
3100 3100 51.201.31 Stream #4 Skip Flag (19.0.10)
5001 5001 51.208.2 Cycle Clock (19.2.2)

5002 5003 51.208.1 Cycle Time (19.2.1)
5003 5005 51.208.0 Detector 0 (N/A))
5004 5007 51.208.0 Detector 1 (N/A))
5005 5009 51.208.0 Detector 2 (N/A)
5006 5011 51.208.0 Detector 3 (N/A)
Mole % for Stream

7001 7001 51.203.0 Mole % - Component #1
7002 7003 51.203.1 Mole % - Component #2
7003 7005 51.203.2 Mole % - Component #3
7004 7007 51.203.3 Mole % - Component #4
2101510-002 rev. AE Page A3

Modbus Reg #
32-bit 16-bit
7005 7009 51.203.4 Mole % - Component #5
7006 7011 51.203.5 Mole % - Component #6
7007 7013 51.203.6 Mole % - Component #7
7008 7015 51.203.7 Mole % - Component #8
7009 7017 51.203.8 Mole % - Component #9
7010 7019 51.203.9 Mole % - Component #10
7011 7021 51.203.10 Mole % - Component #11
7012 7023 51.203.11 Mole % - Component #12
7013 7025 51.203.12 Mole % - Component #13
7014 7027 51.203.13 Mole % - Component #14
7015 7029 51.203.14 Mole % - Component #15
7016 7031 51.203.15 Mole % - Component #16
GPM % for Stream

7017 7033 51.204.0 GPM % - Component #1
7018 7035 51.204.1 GPM % - Component #2
7019 7037 51.204.2 GPM % - Component #3
7020 7039 51.204.3 GPM % - Component #4
7021 7041 51.204.4 GPM % - Component #5
7022 7043 51.204.5 GPM % - Component #6
7023 7045 51.204.6 GPM % - Component #7
7024 7047 51.204.7 GPM % - Component #8
7025 7049 51.204.8 GPM % - Component #9
7026 7051 51.204.9 GPM % - Component #10
7027 7053 51.204.10 GPM % - Component #11
7028 7055 51.204.11 GPM % - Component #12
7029 7057 51.204.12 GPM % - Component #13
7030 7059 51.204.13 GPM % - Component #14
7031 7061 51.204.14 GPM % - Component #15
7032 7063 51.204.15 GPM % - Component #16
Floats for Stream

7033 7065 51.202.0 BTU - Dry(15.4.5)
7034 7067 51.202.1 BTU - Saturated(15.4.6)
7035 7069 51.202.2 Specific Gravity(15.4.9)
7036 7071 51.202.3 Compressibility(15.4.11)
7037 7073 51.202.4 WOBBE Index(15.4.7)
7038 7075 51.202.6 Total UN-normalized mole(15.4.12)
Page A4 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
7039 7077 51.202.13 Total GPM (15.4.13)
7040 7079 51.202.8 Ideal BTU (15.4.4)
7041 7081 51.202.9 Density Normal (15.4.10)
7042 7083 51.202.10 Inferior WOBBE (15.4.8)
7043 7085 51.202.11 Methane Number (15.4.27)
7044 7087 51.202.12 Speed of Sound (15.4.54)
7045 7089 51.241.0 Rolling Average #1

7046 7091 51.241.1 Rolling Average #2
7047 7093 51.241.2 Rolling Average #3
7048 7095 51.241.3 Rolling Average #4
7049 7097 51.241.4 Rolling Average #5
7050 7099 51.241.5 Rolling Average #6
7051 7101 51.241.6 Rolling Average #7
7052 7103 51.241.7 Rolling Average #8
7053 7105 51.241.8 Rolling Average #9
7054 7107 51.241.9 Rolling Average #10
7055 7109 51.241.10 Rolling Average #11
7056 7111 51.241.11 Rolling Average #12
7057 7113 51.241.12 Rolling Average #13
7058 7115 51.241.13 Rolling Average #14
7059 7117 51.241.14 Rolling Average #15
7060 7119 51.241.15 Rolling Average #16
7061 7121 51.206.0 24 Hour Average for Component #1

2101510-002 rev. AE Page A5

Modbus Reg #
32-bit 16-bit
7077 7153 51.207.0 Previous 24 Hour Average for Component #1
Floating Point Register Group - Transmitter

7200 7200 51.202.7 Ground Reference (N/A)
7201 7202 51.202.18 Power (12.247.9)
7202 7204 51.202.19 Mandrel Temp (12.247.7)
7203 7206 51.202.20 Column 1 Pressure (12.247.5)
7204 7208 51.202.21 Column 2 Pressure (12.247.6)
7205 7210 51.202.7 Analog Input #6 - Spare (N/A)
7206 7212 51.202.7 Ambient Temp (N/A)
7207 7214 51.202.7 Voltage Reference (N/A)
7208 7216 51.202.7 (N/A)
7209 7218 51.233.0 Calibration Standard - Component #1 (15.31.0)
Page A6 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
7225 7250 51.205.0 Response Factor - Component #1 (15.5.0)
7241 7282 51.239.0 Alt Calibration Standard - Component #1 (15.40.0)
7257 7314 51.240.0 Alt Response Factor - Component #1 (15.43.0)
2101510-002 rev. AE Page A7

Modbus Reg #
32-bit 16-bit
7273 7346 51.202.14 Detector 0 value (12.247.0)

7274 7348 51.202.15 Detector 1 value (12.247.1)
7275 7350 51.202.16 Detector 2 value (12.247.2)
7276 7352 51.202.17 Detector 3 value (12.247.3)
Registers 7400-7599 are for stream #1

7401 7401 51.210.0 Mole % - Component #1(C3)
7402 7403 51.210.1 Mole % - Component #2(IC4)
7403 7405 51.210.2 Mole % - Component #3(NC4)
7404 7407 51.210.3 Mole % - Component #4(Neo C5)
7407 7413 51.210.6 Mole % - Component #7(C6+)
7408 7415 51.210.7 Mole % - Component #8(N2)
7409 7417 51.210.8 Mole % - Component #9(C1)
7410 7419 51.210.9 Mole % - Component #10(C02)
7411 7421 51.210.10 Mole % - Component #11(C2)
7412 7423 51.210.11 Mole % - Component #12(C6s)
7414 7427 51.210.13 Mole % - Component #14(C8)
7415 7429 51.210.14 Mole % - Component #15(C9)
7416 7431 51.210.15 Mole % - Component #16(spare)
7417 7433 51.211.0 GPM % - Component #1
7418 7435 51.211.1 GPM % - Component #2
7419 7437 51.211.2 GPM % - Component #3
7420 7439 51.211.3 GPM % - Component #4
7421 7441 51.211.4 GPM % - Component #5
7422 7443 51.211.5 GPM % - Component #6
Page A8 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
7423 7445 51.211.6 GPM % - Component #7
7424 7447 51.211.7 GPM % - Component #8
7425 7449 51.211.8 GPM % - Component #9
7426 7451 51.211.9 GPM % - Component #10
7427 7453 51.211.10 GPM % - Component #11
7428 7455 51.211.11 GPM % - Component #12
7429 7457 51.211.12 GPM % - Component #13
7430 7459 51.211.13 GPM % - Component #14
7431 7461 51.211.14 GPM % - Component #15
7432 7463 51.211.15 GPM % - Component #16
7433 7465 51.209.0 BTU - Dry

7434 7467 51.209.1 BTU - Saturated
7435 7469 51.209.2 Specific Gravity
7436 7471 51.209.3 Compressibility
7437 7473 51.209.4 WOBBE Index
7438 7475 51.209.5 Total UN-normalized mole
7439 7477 51.209.11 Total GPM

7440 7479 51.209.6 Ideal BTU
7441 7481 51.209.7 Density Normal
7442 7483 51.209.8 Inferior WOBBE
7443 7485 51.209.9 Methane Number
7444 7487 51.209.10 Speed of Sound
7445 7489 51.235.0 Rolling Average #1

7446 7491 51.235.1 Rolling Average #2
7447 7493 51.235.2 Rolling Average #3
7448 7495 51.235.3 Rolling Average #4
7449 7497 51.235.4 Rolling Average #5
7450 7499 51.235.5 Rolling Average #6
7451 7501 51.235.6 Rolling Average #7
7452 7503 51.235.7 Rolling Average #8
7453 7505 51.235.8 Rolling Average #9
7454 7507 51.235.9 Rolling Average #10
7455 7509 51.235.10 Rolling Average #11
7456 7511 51.235.11 Rolling Average #12
7457 7513 51.235.12 Rolling Average #13
7458 7515 51.235.13 Rolling Average #14
7459 7517 51.235.14 Rolling Average #15
2101510-002 rev. AE Page A9

Modbus Reg #
32-bit 16-bit
7460 7519 51.235.15 Rolling Average #16


7601 7601 51.215.0 Mole % - Component #1(C3)
Page A10 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
7607 7613 51.215.6 Mole % - Component #7(C6+)
7608 7615 51.215.7 Mole % - Component #8(N2)
7609 7617 51.215.8 Mole % - Component #9(C1)
7610 7619 51.215.9 Mole % - Component #10(C02)
7611 7621 51.215.10 Mole % - Component #11(C2)
7617 7633 51.216.0 GPM % - Component #1
7618 7635 51.216.1 GPM % - Component #2
7619 7637 51.216.2 GPM % - Component #3
7620 7639 51.216.3 GPM % - Component #4
7621 7641 51.216.4 GPM % - Component #5
7622 7643 51.216.5 GPM % - Component #6
7623 7645 51.216.6 GPM % - Component #7
7624 7647 51.216.7 GPM % - Component #8
7625 7649 51.216.8 GPM % - Component #9
7626 7651 51.216.9 GPM % - Component #10
7627 7653 51.216.10 GPM % - Component #11
7628 7655 51.216.11 GPM % - Component #12
7629 7657 51.216.12 GPM % - Component #13
7630 7659 51.216.13 GPM % - Component #14
7631 7661 51.216.14 GPM % - Component #15
7632 7663 51.216.15 GPM % - Component #16
7633 7665 51.214.0 BTU - Dry

7634 7667 51.214.1 BTU - Saturated
7637 7673 51.214.4 WOBBE Index
7639 7677 51.214.11 Total GPM
7640 7679 51.214.6 Ideal BTU
7641 7681 51.214.7 Density Normal
7642 7683 51.214.8 Inferior WOBBE
7643 7685 51.214.9 Methane Number
2101510-002 rev. AE Page A11

Modbus Reg #
32-bit 16-bit
7644 7687 51.214.10 Speed of Sound
7645 7689 51.236.0 Rolling Average #1

7646 7691 51.236.1 Rolling Average #2
7647 7693 51.236.2 Rolling Average #3
7648 7695 51.236.3 Rolling Average #4
7649 7697 51.236.4 Rolling Average #5
7650 7699 51.236.5 Rolling Average #6
7651 7701 51.236.6 Rolling Average #7
7652 7703 51.236.7 Rolling Average #8
7653 7705 51.236.8 Rolling Average #9
7654 7707 51.236.9 Rolling Average #10
7655 7709 51.236.10 Rolling Average #11
7656 7711 51.236.11 Rolling Average #12
7657 7713 51.236.12 Rolling Average #13
7658 7715 51.236.13 Rolling Average #14
7659 7717 51.236.14 Rolling Average #15
7660 7719 51.236.15 Rolling Average #16

Page A12 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit

7801 7801 51.220.0 Mole % - Component #1(C3)
7807 7813 51.220.6 Mole % - Component #7(C6+)
7808 7815 51.220.7 Mole % - Component #8(N2)
7809 7817 51.220.8 Mole % - Component #9(C1)
7810 7819 51.220.9 Mole % - Component #10(C02)
7811 7821 51.220.10 Mole % - Component #11(C2)
7817 7833 51.221.0 GPM % - Component #1
7818 7835 51.221.1 GPM % - Component #2
7819 7837 51.221.2 GPM % - Component #3
7820 7839 51.221.3 GPM % - Component #4
7821 7841 51.221.4 GPM % - Component #5
7822 7843 51.221.5 GPM % - Component #6
7823 7845 51.221.6 GPM % - Component #7
7824 7847 51.221.7 GPM % - Component #8
7825 7849 51.221.8 GPM % - Component #9
7826 7851 51.221.9 GPM % - Component #10
7827 7853 51.221.10 GPM % - Component #11
2101510-002 rev. AE Page A13

Modbus Reg #
32-bit 16-bit
7828 7855 51.221.11 GPM % - Component #12
7829 7857 51.221.12 GPM % - Component #13
7830 7859 51.221.13 GPM % - Component #14
7831 7861 51.221.14 GPM % - Component #15
7832 7863 51.221.15 GPM % - Component #16
7833 7865 51.219.0 BTU - Dry

7834 7867 51.219.1 BTU - Saturated
7837 7873 51.219.4 WOBBE Index
7839 7877 51.219.11 Total GPM
7840 7879 51.219.6 Ideal BTU
7841 7881 51.219.7 Density Normal
7842 7883 51.219.8 Inferior WOBBE
7843 7885 51.219.9 Methane Number
7844 7887 51.219.10 Speed of Sound
7845 7889 51.237.0 Rolling Average #1

7846 7891 51.237.1 Rolling Average #2
7847 7893 51.237.2 Rolling Average #3
7848 7895 51.237.3 Rolling Average #4
7849 7897 51.237.4 Rolling Average #5
7850 7899 51.237.5 Rolling Average #6
7851 7901 51.237.6 Rolling Average #7
7852 7903 51.237.7 Rolling Average #8
7853 7905 51.237.8 Rolling Average #9
7854 7907 51.237.9 Rolling Average #10
7855 7909 51.237.10 Rolling Average #11
7856 7911 51.237.11 Rolling Average #12
7857 7913 51.237.12 Rolling Average #13
7858 7915 51.237.13 Rolling Average #14
7859 7917 51.237.14 Rolling Average #15
7860 7919 51.237.15 Rolling Average #16

Page A14 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit

8001 8001 51.225.0 Mole % - Component #1(C3)
8007 8013 51.225.6 Mole % - Component #7(C6+)
8008 8015 51.225.7 Mole % - Component #8(N2)
8009 8017 51.225.8 Mole % - Component #9(C1)
8010 8019 51.225.9 Mole % - Component #10(C02)
2101510-002 rev. AE Page A15

Modbus Reg #
32-bit 16-bit
8011 8021 51.225.10 Mole % - Component #11(C2)
8017 8033 51.226.0 GPM % - Component #1
8018 8035 51.226.1 GPM % - Component #2
8019 8037 51.226.2 GPM % - Component #3
8020 8039 51.226.3 GPM % - Component #4
8021 8041 51.226.4 GPM % - Component #5
8022 8043 51.226.5 GPM % - Component #6
8023 8045 51.226.6 GPM % - Component #7
8024 8047 51.226.7 GPM % - Component #8
8025 8049 51.226.8 GPM % - Component #9
8026 8051 51.226.9 GPM % - Component #10
8027 8053 51.226.10 GPM % - Component #11
8028 8055 51.226.11 GPM % - Component #12
8029 8057 51.226.12 GPM % - Component #13
8030 8059 51.226.13 GPM % - Component #14
8031 8061 51.226.14 GPM % - Component #15
8032 8063 51.226.15 GPM % - Component #16
8033 8065 51.224.0 BTU - Dry

8034 8067 51.224.1 BTU - Saturated
8037 8073 51.224.4 WOBBE Index
8039 8077 51.224.11 Total GPM
8040 8079 51.214.6 Ideal BTU
8041 8081 51.214.7 Density Normal
8042 8083 51.214.8 Inferior WOBBE
8043 8085 51.214.9 Methane Number
8044 8087 51.214.10 Speed of Sound
8045 8089 51.238.0 Rolling Average #1

8046 8091 51.238.1 Rolling Average #2
8047 8093 51.238.2 Rolling Average #3
8048 8095 51.238.3 Rolling Average #4
Page A16 2101510-002 rev. AE

Modbus Reg #
32-bit 16-bit
8049 8097 51.238.4 Rolling Average #5
8050 8099 51.238.5 Rolling Average #6
8051 8101 51.238.6 Rolling Average #7
8052 8103 51.238.7 Rolling Average #8
8053 8105 51.238.8 Rolling Average #9
8054 8107 51.238.9 Rolling Average #10
8055 8109 51.238.10 Rolling Average #11
8056 8111 51.238.11 Rolling Average #12
8057 8113 51.238.12 Rolling Average #13
8058 8115 51.238.13 Rolling Average #14
8059 8117 51.238.14 Rolling Average #15
8060 8119 51.238.15 Rolling Average #16

2101510-002 rev. AE Page A17

Modbus Reg #
32-bit 16-bit
Page A18 2101510-002 rev. AE

APPENDIX B TOTALFLOW DEFINITIONS AND ACRONYMS
TERM DEFINITION
Greek letter for mu. Often used in math and engineering as the

symbol for micro. Pronounced as a long u.
FLOs measurement and operational features are housed in this
single unit assembly. The main electronic board (FLO-195 Board),
FLO IMV
communication connection, power, SP, DP and Temperature readings
are all housed in this unit.
Main Electronic Board used in the FLO Computers. It is housed on an
FLO-2100767 Board integrated assembly and includes the IMV. It operates at 195 MHz
while drawing minimal power.
Sec Micro Second.
This Totalflow Flow Computer is housed in a small lightweight
enclosure. Its main feature is its low power, microprocessor based
FLO 6200 units designed to meet a wide range of measurement, monitor and
alarming applications for remote gas systems, while being a cost
effective alternative.
*.CSV file See Comma Separated Values (I.E. spreadsheet format).
*.INI file See Initialization File.
A/D Analog-to-digital.
ABB Inc. Asea, Brown & Boveri, parent company of Totalflow
Gauge pressure plus barometric pressure. Totalflow devices use Static
Absolute Pressure
Pressure (SP) for flow calculations.
The zero point on the absolute temperature scale. It is equal to -273.16
Absolute Zero degrees C, or 0 degrees K (Kelvin), or -459.69 degrees F, or 0 degrees
R (Rankine).
A tower or column that provides contact between natural gas being
Absorber
processed and a liquid solvent.
The process of removing vapors from a stream of natural gas by
Absorption passing the natural gas through liquids or chemicals which have a
natural attraction to the vapors to be removed from the stream.
A factor which is an indication of the tendency for a given gas phase
component to be transferred to the liquid solvent. It is generally
Absorption Factor expressed as A=L/KV where L and V are the moles of liquid and vapor,
and K is the average value of the vapor-liquid equilibrium constant for
the component of concern.
A hydrocarbon liquid used to absorb and recover components from the
Absorption Oil
natural gas being processed.
AC See Alternating Current.
How closely a measured value agrees with the correct value. Usually
Accuracy
expressed as percent of full scale output or reading.
Acid Gas See Gas, Acid.
2101510-002 rev. AE Page B1

TERM DEFINITION
ACK See Acknowledgment.
This refers to a response over a remote communication device to a
Acknowledgment request such as a PING. Basically, saying, "I'm here, and I saw your
request!"
ACM See Analyzer Control Module.
The degree of sound. The nature, cause, and phenomena of the
vibrations of elastic bodies; which vibrations create compressional
Acoustics
waves or wave fronts which are transmitted through various media,
such as air, water, wood, steel, etc.
Active Analog Output Analog Output to a host providing power to the host.
An operational mode used by the LevelMaster for measuring dual float
levels by applying a signal to the primary windings, reading the voltage
Active Mode
level on the secondary windings and using an algorithm to determine
the oil and water levels.
Adapter A mechanism or device for attaching non-mating parts.
ADC See Analog-to-Digital Converter.
A unique memory designation for location of data or the identity of a
Address peripheral device; allows each device on a single communications line
to respond to its own message.
The expansion of a gas, vapor, or liquid stream from a higher pressure
Adiabatic Expansion to a lower pressure in which there is no heat transfer between the gas,
vapor, or liquid and the surroundings.
The process of removing natural gas liquids from a stream of natural
Adsorption gas by passing the natural gas through granular solids which have a
natural attraction to the liquids to be removed from the stream.
A length of wire designed to transmit or receive radio waves. (See also
Aerial
Antenna)
Minute liquid particles suspended in gas. Aerosols will behave like a
fluid and can be transported by pipes and pumping. When aerosols
Aerosol Liquids contact each other they coalesce into droplets. Aerosols may be
present in gas, or may be generated by glow shearing off the skim
inside of a pipeline.
American Gas Association. Trade group representing natural gas
AGA
distributors and pipelines.
American Gas Association Report No. 10, Speed of Sound in Natural
AGA-10 Gas and Other Related Hydrocarbon Gases. Method for calculation of
the speed of sound in gases.
American Gas Association Report No. 3, Orifice Metering of Natural
Gas. Method for calculating gas volume across an Orifice Plate. This
AGA-3
method requires two pressure readings, Differential Pressure (DP) and
Static Pressure (SP).
Page B2 2101510-002 rev. AE

TERM DEFINITION
American Gas Association Report No. 5, Fuel Gas Energy Metering.
AGA-5 Methods (Volume, Mass or Energy) for calculating BTUs without
knowing the composition of the gas.
American Gas Association Report No. 7, Measurement of Gas by
Turbine Meters. Method for calculating gas volume using a Pulse
AGA-7
Meter. This method requires one pressure reading, Static Pressure
(SP).
American Gas Association Report No. 8, Compressibility Factor of
AGA-8 Natural Gas and Related Hydrocarbon Gases. Method for calculating
the Super Compressibility Factor, Fpv.
American Gas Association Report No. 9, Measurement of Gas by
AGA-9 Multipath Ultrasonic Meters. Method for calculating gas based on
transit-times.
AGC Automatic Gain Control
AH See Ampere-Hour.
AI Analog Input
AIU Analyzer Interface Unit.
The simplest homologous series of saturated aliphatic hydrocarbons,
consisting of methane, ethane, propane, butane; also know as olefins.
Alkane
Unsaturated hydrocarbons that contain one or more carbon-carbon
double bonds.
Alkanolamine See Amine.
Unsaturated hydrocarbons that contain one or more carbon-carbon
Alkynes
triple bonds.
Alphanumeric A character set that contains both letters and digits.
An electric current whose direction changes with a frequency
Alternating Current
independent of circuit components.
Totalflow aluminum enclosures have a baked-on Powder Coating
Aluminum Powder
designed to our specifications to ensure paint adhesion, weather
Coating
resistance and durability.
The design of an instrument such that changes in ambient temperature
Ambient Compensation
do not affect the readings of the instrument.
Ambient Conditions The conditions around the transducer (pressure, temperature, etc.).
Ambient Pressure Pressure of the air surrounding a transducer.
The average or mean temperature of the surrounding air which comes
Ambient Temperature
in contact with the equipment and instruments under test.
Any of several liquid compounds containing amino nitrogen generally
used in water solution to remove, by reversible chemical reaction,
Amine (Alkanolamine)
hydrogen sulfide and/or carbon dioxide from gas and liquid
hydrocarbon streams.
Ammeter An instrument used to measure current.
2101510-002 rev. AE Page B3

TERM DEFINITION
Amp See Ampere.
The unit of electrical current. Also milliamp (one thousandth of an amp)
Ampere and micro amp (one millionth of an amp). One amp corresponds to the
flow of about 6 x 1018 electrons per second.
The quantity of electricity measured in ampere-hours (Ah) which may
Ampere-Hour be delivered by a cell or battery under specified conditions. A current of
one ampere flowing for one hour.
The ratio of the output of a secondary cell or battery, measured in
Ampere-Hour Efficiency ampere-hours, to the input required to restore the initial state of charge,
under specified conditions.
A device which draws power from a source other than the input signal
Amplifier and which produces as an output an enlarged reproduction of the
essential features of its input.
The highest value reached by voltage, current or power during a
Amplitude
complete cycle.
Where audio signals increase and decrease the amplitude of the
Amplitude Modulation
"carrier wave".
The Y-axis range of a graphic display of data in either the time or
Amplitude Span
frequency domain. Usually a log display (dB) but can also be linear.
AMU See Analog Measurement Unit.
Generic reference to the Measurement unit. See Analog Measurement
AMU/IMV
Unit and Integral Multivariable Transducer for more definition.
A system in which data is represented as a continuously varying
Analog
voltage/current.
Analog Input Data received as varying voltage/current.
Analog Measurement A transducer for converting energy from one form to another. (e.g.
Unit Static and Differential pressure to electrical signals)
A voltage or current signal that is a continuous function of the
Analog Output measured parameter. Data that is transmitted as varying
voltage/current.
A trigger that occurs at a user-selected point on an incoming analog
Analog Trigger signal. Triggering can be set to occur at a specific level on either an
increasing or a decreasing signal (positive or negative slope).
Analog-to-Digital An electronic device, often an integrated circuit, that converts an analog
Converter voltage to a number.
The primary component of the NGC8200s modular design is the
analytical module. This module comes in a 12VDC or a 24VDC
configuration and contains the GC Module, Analytical Processing
Analytical Module system and manifold. Replacement of this component is enhanced by
the single bolt removal feature. This module may also be broken down
into the GC module, manifold assembly and analytical processor
assembly.
Page B4 2101510-002 rev. AE

TERM DEFINITION
Totalflow Analytical Module assembly contains the GC Module,
Analytical Module Manifold and Analytical Processor. The modular design features Single
Bolt removal.
The Analytical Processor board interfaces with the analog circuits to
Analytical Processor monitor temperatures, and pressures, and also control the processes.
Assembly The data generated by the Analytical Processor is passed to the Digital
Controller board.
Analyzer Control Module Consists of various electronic components used for analysis.
Anemometer An instrument for measuring and/or indicating the velocity of air flow.
Annealed Toughen (steel or glass) by a process of gradually heating and cooling,
Annunciator Display of a status on a screen.
ANSI American National Standards Institute.
A length of wire or similar that radiates (such as a transmitting antenna)
Antenna or absorbs (such as a radio antenna) radio waves. The two basic types
are: Yagi (directional) or Omni (bi-directional).
AO Analog Output
AP See Absolute Pressure.
American Petroleum Institute Report No. 14.3 addresses the 1992
API 14.3 equation regarding the AGA-3 method for calculating gas volume
across an Orifice Plate.
American Petroleum Institute Report No. 21.1 addresses the equation
API 21.1 regarding AGA-8 Fpv or Supercompressibility Factor and the energy
content of the gas.
An arbitrary scale expressing the relative density of liquid petroleum
products. The scale is calibrated in degrees API. The formula is:
API Gravity 141.5
DegAPI = 131.5
( 60 F / 60 F
where =relative density.
A file containing historical records in a compressed format for more

efficient long term storage and transfer. Totalflow archive records are
Archive
non-editable, meaning that when they are stored they may not be
changed. These records are used during an audit of data.
Techniques for producing oil after depletion or in lieu of natural drives;
Artificial Drives includes water flooding, natural gas re-injection, inert gas injection, flue
gas injection and in-situ combustion.
Any of the techniques, other than natural drives, for bringing oil to the
Artificial Lift
surface.
American Standard Code for Information Interchange. A very popular
ASCII standard method of encoding alphanumeric characters into 7 or 8
binary bits.
ASME American Society of Mechanical Engineers.
2101510-002 rev. AE Page B5

TERM DEFINITION
ASTM American Society for Testing and Materials (ASTM International).
ASTM International Standard Practice for calculating heat value,
ASTM D 3588
compressibility factor and relative density of gaseous fuels.
A communications protocol where information can be transmitted at an
Asynchronous arbitrary, unsynchronized point in time, without synchronization to a
reference time or "clock".
ATC Automatic temperature compensation.
Term used for European Unions New Approach Directive 94/9/EC
ATEX which concerns equipment and protective systems intended for use in
potentially explosive atmospheres.
A unit of pressure; the pressure that will support a column of mercury
Atmosphere (one)
760 mm high at 0 C.
The pressure exerted on the earth by the earths atmosphere (air and
water vapor). A pressure of 760 mm of mercury, 29.92 inches of
Atmospheric Pressure mercury, or 14.696 pounds per square inch absolute is used as a
(scientific) standard for some measurements. Atmospheric pressure
may also refer to the absolute ambient pressure at any given location.
Audio Frequency Generally in the range 20 Hz to 20 KHz.
To examine or verify data for accuracy. Totalflows DB1 and DB2
Audit records may be edited to generate a more accurate representation of
data information.
Using the Long Term Archive files to justify changes made to records
that more accurately reflects the correct data. Peripheral information
Audit Trail
used to edit data is recorded without exception, to justify the accuracy
of the edited data records.
Automatic Frequency Similar to Automatic Fine Tune (AFT). A circuit that keeps a receiver in
Control tune with the wanted transmission.
AWG American Wire Gage.
AWG Acronym for American Wire Gauge.
Pressure against which a fluid is flowing. May be composed of friction
Back Pressure in pipes, restrictions in pipes, valves, pressure in vessels to which fluid
is flowing, hydrostatic head, or other resistance to fluid flow.
Technique used in chromatography to reverse direction of the flow after
the lighter components have been measured, allowing the heavier
Backflush
components to remain in the column until measured, shortening the
length of the column.
Data is acquired by a DAQ system while another program or
Background Acquisition
processing routine is running without apparent interruption.
The total noise floor from all sources of interference in a measurement
Background Noise
system, independent of the presence of a data signal.
A system, device, file or facility that can be used as an alternative in
Backup
case of a malfunction or loss of data.
Page B6 2101510-002 rev. AE

TERM DEFINITION
The range of frequencies available for signaling; the difference between
Bandwidth
the highest and lowest frequencies of a band expressed in Hertz.
Bar is equal to 1 atmosphere of pressure. I.e. .987 Standard
Bar
atmospheric pressure or 14.5 lbs./psia.
Barometer An instrument which measures atmospheric pressure.
A unit of liquid volume measurement in the petroleum industry that
equals 42 U.S. gallons (.159 cubic meters) for petroleum or natural gas
Barrel
liquid products, measured at 60 degrees Fahrenheit and at an
equilibrium vapor pressure.
The pressure used as a standard in determining gas volume. Volumes
are measured at operating pressures and then corrected to base
pressure volume. Base pressure is normally defined in any gas
Base Pressure
measurement contract. The standard value for natural gas in the United
States is 14.73 psia, established by the American National Standards
Institute as standard Z-132.1 in 1969.
Basic Sediment and Waste that collects in the bottom of vessels and tanks containing
Water petroleum or petroleum products.
Two or more electrochemical cells electrically interconnected in an
Battery appropriate series/parallel arrangement to provide the required
operating voltage and current levels.
Unit of signaling speed. The speed in baud is the number of discrete
Baud conditions or events per second. If each event represents only one bit
condition, baud rate equals bits per second (bps).
Serial communications data transmission rate expressed in bits per
Baud Rate
second (b/s).
Bbl See Barrel.
Abbreviation for one billion standard cubic feet or one thousand MMcf
Bcf
or one million Mcf.
A liquefied hydrocarbon product composed primarily of butanes and
BG Mix
natural gasoline.
Term used when calibrating. Amounts to offset the actual measurement
taken. On a LevelMaster, it refers to adjusting the measurement of the
float level to agree with a calibrated measurement. On an RTD
Bias
(Resistant Thermal Detector), it refers to adjusting the measurement of
the temperature to agree with a calibrated temperature. This figure
maybe either a positive or negative figure.
A very low-level DC current generated by the panel meter and
BIAS Current superimposed on the signal. This current may introduce a measurable
offset across a very high source impedance.
Binary Number System based on the number 2. The binary digits are 0 and 1.
Binary-Coded Decimal A code for representing decimal digits in a binary format.
2101510-002 rev. AE Page B7

TERM DEFINITION
Basic Input/Output System. A program, usually stored in ROM, which
provides the fundamental services required for the operation of the
BIOS
computer. These services range from peripheral control to updating the
time of day.
Bipolar A signal range that includes both positive and negative values.
Bipolar Transistor The most common form of transistor.
Binary Digit - the smallest unit of binary data. One binary digit, either 0
Bit
or 1. See also byte.
Bits Per Second Unit of data transmission rate.
Technological changes to the DC and ACM Modules, decreasing noise
Blue Dot Technology by changing ground. Allows amplification of the results, gains
resolution.
Common name used to identify the Main Electronic Board. Also called
Board
Motherboard, Engine Card and Circuit Board.
The temperature at which a substance in the liquid phase transforms to
Boiling Point the gaseous phase; commonly refers to the boiling point of water which
is 100C (212F) at sea level.
Abbreviated BSL. Software enabling user to communicate with the
Bootstrap Loader PCBA for the purpose of programming the FLASH memory in the
microcontroller.
Bouncing is the tendency of any two metal contacts in an electronic
device to generate multiple signals as the contacts close or open.
When you press a key on your computer keyboard, you expect a single
contact to be recorded by your computer. In fact, however, there is an
Bounce
initial contact, a slight bounce or lightening up of the contact, then
another contact as the bounce ends, yet another bounce back, and so
forth. A similar effect takes place when a switch made using a metal
contact is opened.
A liquefied hydrocarbon product composed primarily of butanes and
BP Mix
propane.
BPS See Bits Per Second.
Generally a short-circuit on a PC board caused by solder joining two
Bridge
adjacent tracks.
Bridge Resistance See Input impedance and Output impedance.
Energy required to raise one pound of water one degree Fahrenheit.
British Thermal Unit One pound of water at 32 F requires the transfer of 144 BTUs to
freeze into solid ice.
Browser Software which formats Web pages for viewing; the Web client
BS&W See Basic Sediment and Water.
BSL See Bootstrap Loader.
Btu See British Thermal Unit.
Page B8 2101510-002 rev. AE

TERM DEFINITION
A numerical representation of the heating value of natural gas which
may be calculated or presented to indicate varying relationships (e.g.,
the number of Btu contained in one standard cubic foot or the number
Btu Factor
of MMBtu contained in one Mcf of gas. The factor for a given
relationship will vary depending upon whether the gas is dry or
saturated.
A method of allocating costs between different operations or between
Btu Method different products based upon the heat content of products produced in
the various operations or of the various produced products.
A measure of the heat available or released when one cubic foot of gas
Btu per Cubic Foot
is burned.
Heating value contained in cubic foot of natural gas measured and
Btu, Dry calculated free of moisture content. Contractually, dry may be defined
as less than or equal to seven pounds of water per Mcf.
The number of Btus contained in a cubic foot of natural gas fully
Btu, Saturated saturated with water under actual delivery pressure, temperature and
gravity conditions. See BTU, DRY.
Used to express the heating content of gas. See British Thermal Units
Btu/CV
or Calorific Value.
Refers to the interface program or software that operates the Btu
BtuMMI
Analyzer.
(1) A temporary storage device used to compensate for a difference in
data rate and data flow between two devices (typically a computer and
Buffer
a printer); also called a spooler; (2) An amplifier to increase the drive
capability, current or distance, of an analog or digital signal.
The maximum pressure applied to a transducer sensing element or
Burst Pressure
case without causing leakage.
A data path shared by many devices (e.g., multipoint line) with one or
BUS
more conductors for transmitting signals, data, or power.
A type of controller with the ability to read and write to devices on the
Bus Master
computer bus.
Busbar A heavy, rigid conductor used for high voltage feeders.
A saturated hydrocarbon (Alkane) with four carbon atoms in its
molecule (C4H10). A gas at atmospheric pressure and normal
temperature, but easily liquefied by pressure. Generally stored and
Butane (C4H10)
delivered in liquefied form and used as a fuel in gaseous form, obtained
by processing natural gas as produced and also from a process in
petroleum refining. Contains approximately 3,260 Btu per cubic foot.
Butane, Normal see Normal Butane.
2101510-002 rev. AE Page B9

TERM DEFINITION
A saturated hydrocarbon (Alkane) with four carbon atoms in its
molecule (C4H8). A gas at room temperature and pressure, but easily
liquefied by lowering the temperature or raising the pressure. This gas
Butylene (C4H8)
is colorless, has a distinct odor, and is highly flammable. Although not
naturally present in petroleum in high percentages, they can be
produced from petrochemicals or by catalytic cracking of petroleum.
A group of binary digits that combine to make a word. Generally 8 bits.
Half byte is called a nibble. Large computers use 16 bits and 32 bits.
Byte
Also used to denote the amount of memory required to store one byte
of data.
C10H22 The molecular formula for Decane.
C1H4 The molecular formula for Methane.
C2H4 The molecular formula for Ethylene.
C2H6 The molecular formula for Ethane.
C3H6 The molecular formula for Propylene.
C3H8 The molecular formula for Propane.
C4H10 The molecular formula for Butane.
C4H8C The molecular formula for Butylene.
C5+ A standard abbreviation for Pentanes Plus (IC5, NC5 and C6+).
C5H12 The molecular formula for Pentane.
C6+ A standard abbreviation for Hexane Plus.
C6H14 The molecular formula for Hexane.
C7H16 The molecular formula for Heptane.
C8H18 The molecular formula for Octane.
C9H20 The molecular formula for Nonane.
Fast memory used to improve the performance of a CPU. Instructions
Cache Memory that will soon be executed are placed in cache memory shortly before
they are needed. This process speeds up the operation of the CPU.
To ascertain, usually by comparison with a standard, the locations at
which scale or chart graduations should be placed to correspond to a
series of values of the quantity which the instrument is to measure,
Calibrate receive or transmit. Also, to adjust the output of a device, to bring it to a
desired value, within a specified tolerance for a particular value of the
input. Also, to ascertain the error in the output of a device by checking it
against a standard.
The quantity of thermal energy required to raise one gram of water 1C
Calorie
at 15C.
An apparatus which is used to determine the heating value of a
Calorimeter
combustible material.
Capacitor An electronic component that stores electrical charge.
Page B10 2101510-002 rev. AE

TERM DEFINITION
The total number of ampere-hours (or watt-hours) that can be
Capacity
withdrawn from a cell/battery under specified conditions of discharge.
CAR Carrier Gas (located on NGC8200 series Feed-Through Assembly).
Base of all hydrocarbons and is capable of combining with hydrogen in
many proportions, resulting in numberless hydrocarbon compounds.
Carbon
The carbon content of a hydrocarbon determines, to a degree, the
hydrocarbon's burning characteristics and qualities.
Colorless, odorless and slightly acid-tasting gas, consisting of one atom
of carbon joined to two atoms of oxygen. C02. Produced by combustion
Carbon Dioxide
or oxidation of materials containing carbon. Commonly referred to as
dry ice when in its solid form.
Totalflow recommends that Helium be used as a carrier gas. Carrier
gas is used in the Mobile Phase of chromatography, pushing the
Carrier Gas
sample gas through the columns (Stationary Phase). Because Helium
has no heating value, it does not affect the Btu values.
Casinghead Gas Natural gas that is produced from oil wells along with crude oil.
A substance that speeds up a chemical reaction without being
Catalyst consumed itself in the reaction. A substance that alters (usually
increases) the rate at which a reaction occurs.
Catalytic The process of altering, accelerating or instigating a chemical reaction.
An electrode through which current leaves any nonmetallic conductor.
An electrolytic cathode is an electrode at which positive ions are
Cathode discharged, or negative ions are formed, or at which other reducing
reactions occur. The negative electrode of a galvanic cell; of an
electrolytic capacitor.
The boiling of a liquid caused by a decrease in pressure rather than an
Cavitation
increase in temperature.
Cubic Centimeters. Measurement unit for measuring volume or
CC
capacity in one hundredth of a meter.
CC Acronym for Cubic Centimeter.
C-Code C language (IEC supported programming language)
CCU See DosCCU, WINCCU, PCCU or WEBCCU.
CCV See Closed Circuit Voltage.
Cd Coefficient of Discharge factor.
CDPD Cellular Digital Packet Data
CE European Community Certification Bureau.
The basic electrochemical unit used to generate or store electrical
Cell
energy.
A temperature scale defined by 0C at the ice point and 100C at
Celsius (centigrade)
boiling point of water at sea level.
2101510-002 rev. AE Page B11

TERM DEFINITION
European Committee for Electro-technical Standardization. Also known
CENELEC
as the European Standards Organization.
Centimeter Acronym c. Metric measurement equal to .3937 inch.
The central part of a computer system that performs operations on
Central Processing Unit data. In a personal computer the CPU is typically a single
microprocessor integrated circuit.
High-temperature compositions of metal oxides used to insulate a pair
of thermocouple wires The most common are Alumina (Al2O3),
Beryllium (BeO), and Magnesia (MgO). Their application depends upon
Ceramic Insulation
temperature and type of thermocouple. High-purity alumina is required
for platinum alloy thermocouples. Ceramic insulators are available as
single and multihole tubes or as beads.
The process of submitting equipment to specific tests to determine that
Certification
the equipment meets the specifications or safety standards.
Cf A standard abbreviation for Cubic foot.
Configuration File. When saving new configuration files, the file is
CFG
saved as a *.cfg file.
CFM The volumetric flow rate of a liquid or gas in cubic feet per minute.
A letter, digit or other symbol that is used as the representation of data.
Character
A connected sequence of characters is called a character string.
Detailed information pertaining to its description. The XFC stores this
Characteristics information in the PROM chip. A feature or quality that makes
somebody or something recognizable.
The conversion of electrical energy, provided in the form of a current
Charge
from an external source, into chemical energy within a cell or battery.
Another name for integrated circuit or the piece of silicon on which
Chip
semiconductors are created.
An instrument used in chemical analysis, to determine the make-up of
various substances, and often used to determine the Btu content of
Chromatograph natural gas. Chromatography- A method of separating gas compounds
by allowing it to seep through an adsorbent so that each compound is
adsorbed in a separate layer.
Communication Interface Module. Totalflows version is called TFIO
CIM
Communication Interface Module.
1. The complete path between two terminals over which one-way or
two-way communications may be provided. 2. An electronic path
between two or more points, capable of providing a number of
channels. 3. A number of conductors connected together for the
Circuit purpose of carrying an electrical current. 4. An electronic closed-loop
path among two or more points used for signal transfer. 5. A number of
electrical components, such as resistors, inductances, capacitors,
transistors, and power sources connected together in one or more
closed loops.
Page B12 2101510-002 rev. AE

TERM DEFINITION
Sometimes abbreviated PCB. Printed circuit boards are also called
cards. A thin plate on which chips and other electronic components are
placed. They fall into the following categories:
Motherboard: Typically, the mother board contains the CPU, memory
and basic controllers for the system. Sometimes call the system board
or main board.
Expansion board: Any board that plugs into one of the computer's
expansion slots, including controller boards, LAN cards, and video
Circuit board adapters.
Daughter Card: Any board that attaches directly to another board.
Controller board: A special type of expansion board that contains a
controller for a peripheral device.
Network Interface Card (NIC): An expansion board that enables a PC to
be connected to a local-area network (LAN).
Video Adapter: An expansion board that contains a controller for a
graphics monitor.
Class 1 refers to the presence of flammable gases, vapors or liquids.
Division 1 indicates an area where ignitable concentrations of
Class 1, Division 1
flammable gases, vapors or liquids can exist all of the time or some of
the time under normal operating conditions.
Division 2 indicates an area where ignitable concentrations of
Class 1, Division 2
flammable gases, vapors or liquids are not likely to exist under normal
operating conditions.
Zone 0 refers to a place in which an explosive atmosphere consisting of
Class 1, Zone 0
a mixture with air of flammable substances in the form of gas, vapor or
mist is present continuously or for long periods or frequently.
Class 1, Zone 1
mist is likely to occur in normal operation occasionally.
Class 1, Zone 2
mist is not likely to occur in normal operation.
Gas that has no particles larger than one micron and no more than one
Clean Gas
milligram of solids per cubic meter.
Clear To restore a device to a prescribed initial state, usually the zero state.
The source(s) of timing signals for sequencing electronic events (e.g.
Clock
synchronous data transfer).
The difference in potential between the terminals of a cell/battery when
Closed Circuit Voltage
it is discharging (on- load condition).
CM Acronym for Cubic Meter.
2101510-002 rev. AE Page B13

TERM DEFINITION
Cm Acronym for Centimeter.
CMM Acronym for Cubic Meter per Minute.
CMOS See Complimentary Metal-Oxide-Semiconductor.
CNG See Compressed Natural Gas
CO2 A standard abbreviation for Carbon Dioxide.
A methane-rich, sulfur-free natural gas contained within underground
Coalbed Methane
coal beds.
The ratio of the change in length or volume of a body to the original
Coefficient of expansion
length or volume for a unit change in temperature.
Coil A conductor wound in a series of turns.
A rebooting technique which will clear all operational errors, loose all
Cold Start data files, but will not damage configuration files if stored on the
SDRIVE.
Totalflow insulated and heated enclosure designed to house either the
Cold Weather Enclosure
NGC8200 or Btu 8000/8100 Chromatographs in inclement climates.
The semiconductor region in a bipolar junction transistor through which
Collector
a flow of charge carriers leaves the base region.
Hardware component used in gas chromatography to separate
Column
components into measurable units.
Classification of liquid substances that will burn on the basis of flash
points. A combustible liquid means any liquid having a flash point at or
above 37.8C (100F) but below 93.3C (200F), except any mixture
Combustible
having components with flash points of 93.3C (200F) or higher, the
total of which makes up 99 percent or more of the total volume of the
mixture.
Comma Separated These file types are importable records used by spreadsheet programs
Values to display and manipulate data.
Transmission and reception of data among data processing equipment
Communication
and related peripherals.
Comm. Port (abbreviation) refers to the host computer's physical
communication's port being used to communicate with the equipment.
Communication Port Used by Totalflow when discussing local or remote communication with
various equipment including the XFC, FCU, XRC, RTU and
LevelMaster etc.
Compensation An addition of specific materials or devices to counteract a known error.
Family of logic devices that uses p-type and n-type channel devices on
Complimentary Metal-
the same integrated circuit. It has the advantage of offering medium
Oxide-Semiconductor
speed and very low power requirements.
(1) A small object or program that performs a specific function and is
designed in such a way to easily operate with other components and
Component
applications. Increasingly, the term is being used interchangeably with
applet. (2) A part of a device.
Page B14 2101510-002 rev. AE

TERM DEFINITION
A gas or mixture of gases having, in a container an absolute pressure
exceeding 40 psi at 21.1C (70F). A gas or mixture having in a
container, an absolute pressure exceeding 104 psi at 54.4C (130F)
Compressed Gas
regardless of the pressure at (21.1C (70F). A liquid having a vapor
pressure exceeding 40 psi at 37.8C (70F) as determined by ASTM D-
323-72.
Natural gas in high-pressure surface containers that is highly
compressed (though not to the point of liquefaction). CNG is used
Compressed Natural
extensively as a transportation fuel for automobiles, trucks and buses in
Gas
some parts of the world. Small amounts of natural gas are also
transported overland in high-pressure containers.
The property of a material which permits it to decrease in volume when
subjected to an increase in pressure. In gas-measurement usage, the
Compressibility
compressibility factor "Z" is the deviation from the ideal Boyle and
Charles' law behavior. See SUPERCOMPRESSIBILITY FACTOR.
Compressibility Factor See Supercompressibility Factor.
A factor usually expressed as z which gives the ratio of the actual
volume of gas at a given temperature and pressure to the volume of
Compressibility Factor
gas when calculated by the ideal gas law without any consideration of
the compressibility factor.
Concentration Amount of solute per unit volume or mass of solvent or of solution.
Concurrent Performing more than one task at a time.
1) The liquid formed by the condensation of a vapor or gas; specifically,
the hydrocarbon liquid separated from natural gas because of changes
in temperature and pressure when the gas from the reservoir was
Condensate
delivered to the surface separators. 2) A term used to describe light
liquid hydrocarbons separated from crude oil after production and sold
separately.
Condensation Liquefaction of vapor.
Condensed Phases The liquid and solid phases; phases in which particles interact strongly.
Condensed States The solid and liquid states.
The conveying of electrical energy or heat through or by means of a
Conduction
conductor.
The Configuration number is a suffix of the serial number which defines
Configuration No.
the characteristics of the unit.
A local user interface typically used with custom applications that are
Console Mode not supported through any other mechanism. Also referred to as Printer
Console Mode.
Contact Current carrying part of a switch, relay or connector.
The time required, in an analog input or output system, from the
moment a channel is interrogated (such as with a read instruction) to
Conversion Time
the moment that accurate data is available. This could include switching
time, settling time, acquisition time, A/D conversion time, etc.
2101510-002 rev. AE Page B15

TERM DEFINITION
Another computer processor unit that operates in conjunction with the
Coprocessor standard CPU. Can be used to enhance execution speed. For example,
the 8087 is designed to perform floating point arithmetic.
COR See Corrected Runtime.
Correction to signal made to decrease/increase ZERO phase and
Corrected Runtime
eliminate the shift between RT and COR for increased accuracy.
Cos See Cosine.
Cosine The sine of the complement of an arc or angle.
Counterclockwise Movement in the direct opposite to the rotation of the hands of a clock.
The number of time intervals counted by the dual-slope A/D converter
Counts and displayed as the reading of the panel meter, before addition of the
decimal point.
Cycles per second; the rate or number of periodic events in one
CPS
second, expressed in Hertz (Hz).
CPU See Central Processing Unit.
CPUC California Public Utilities Commission
CRC See Cyclic Redundancy Check.
A gas processing plant which is capable of producing natural gas
Cryogenic Plant
liquids products, including ethane, at very low operating temperatures.
CSA International: Formerly Canadian Standards Association.
CSA
Canadian certification agency.
CTS Communication abbreviation for Clear To Send.
Three-dimensional shape with six equal sides. Used in measuring
Cubic
volume.
Cubic Centimeter Acronym CC. Metric volume equal to a 1 Centimeter to the 3rd power.
The most common unit of measurement of gas volume in the US. It is
Cubic Foot the amount of gas required to fill a volume of one cubic foot under
stated conditions of temperature, pressure, and water vapor.
The quantity of gas that occupies one cubic foot under pressure and
Cubic Foot Metered
temperature conditions in the meter.
That quantity of gas which under a pressure of 14.73 psia and at a
Cubic Foot, Standard temperature of 60 degrees occupies a volume of one cubic foot without
adjustment for water vapor content.
Cubic Meter Acronym CM. Metric volume equal to 35.31467 Cubic Feet.
Acronym CMM. Metric flow rate equal to 35.31467 Cubic Feet per
Cubic Meter Per Minute
Minute.
The total number of ampere-hours (or watt hours) that can be
Cumulative Capacity withdrawn from a cell/battery under specified conditions of discharge
over a predetermined number of cycles or the cycle life.
Page B16 2101510-002 rev. AE

TERM DEFINITION
Current is measured in amps (milliamps and micro amps). It is the
passage of electrons. Conventional current flows from positive to
Current
negative. Electrons flow from negative to positive - called "electron
flow".
Dots used to indicate the location of the next character or symbol to be
Cursor
entered.
The legal and commercial transfer of a commodity such as natural gas,
Custody Transfer
LNG, etc. from one party to another.
Custody Transfer The Custody Transfer Transaction is the hand-off of the physical
Transaction commodity from one operator to another.
Cut-Off Voltage The cell/battery voltage at which the discharge is terminated.
CV Calorific Value. European value of heating content.
CV1 Column 1 Vent (located on NGC8200 series Feed-Through Assembly).
CV2 Column 2 Vent (located on NGC8200 series Feed-Through Assembly).
CWE Cold Weather Enclosure.
One complete sequence of events. One complete alteration of an AC
Cycle current or Volt. The discharge and subsequent charge of a
rechargeable cell/battery is called a cycle.
The number of cycles under specified conditions which were available
Cycle Life from a rechargeable cell/battery before it fails to meet specified criteria
as to performance.
The time usually expressed in seconds for a controller to complete one
Cycle Time
on/off cycle.
An ongoing verification of the validity of transmitted and received data
Cyclic Redundancy
providing assurance that the message conforms to a pre-agreed upon
Check
convention of communications.
D/A See Digital-to-analog.
D/I See Digital Input.
D/O See Digital Output.
DAC See Digital to Analog Converter.
DACU Data Acquisition Control Unit.
Gathering information from sources such as sensors and AMUs in an
accurate, timely and organized manner. Modern systems convert this
Data Acquisition
information to digital data, which can be stored and processed by a
computer.
Physically, locally or remotely, retrieving data stored with a Totalflow
Data Collect unit. This data is typically stored in records located in a data base
format.
DB See Decibel.
2101510-002 rev. AE Page B17

TERM DEFINITION
Acronym for Data Base 1. This refers to the previous data base
DB1
structure used to store data in Totalflow products.
Acronym for Data Base 2. This refers to the current data base structure
DB2
used to store data in Totalflow products.
DC See Direct Current
DCD Communication abbreviation for Data Carrier Detect
DCS/PLC Distribution Control System/Programmable Logic Controller
See Digital Data Exchange. Also called Dynamic Data Exchange. May
DDE
refer to Totalflows DDE Server TDS32.
Portable pressure tester used to check calibration and to calibrate
Dead Weight Tester
AMUs utilizing a system of calibrated weights.
De-bouncing is any kind of hardware device or software that ensures
that only a single signal will be acted upon for a single opening or
closing of a contact. When you press a key on your computer keyboard,
you expect a single contact to be recorded by your computer. In fact,
however, there is an initial contact, a slight bounce or lightening up of
De-bounce
the contact, then another contact as the bounce ends, yet another
bounce back, and so forth. A similar effect takes place when a switch
made using a metal contact is opened. The usual solution is a de-
bouncing device or software that ensures that only one digital signal
can be registered within the space of a given time (usually milliseconds)
A hydrocarbon (Alkane) flammable colorless liquid with ten carbon
Decane (C10H22)
atoms.
A logarithmic measure of the ratio of two signal levels. A practical unit
Decibel
of gain.
Decimal A numbering system based on 10.
A value assigned or an action taken automatically unless another is
Default
specified.
An incremental value in the temperature scale, i.e., there are 100
degrees between the ice point and the boiling point of water in the
Degree
Celsius scale and 180F between the same two points in the
Fahrenheit scale.
Point at which gas leaves a transporter's system completing a sale or
Delivery Point transportation service transaction between the pipeline company and a
sale or transportation service customer.
That 24-hour period specified by a supplier-user contract for purposes
of determining the purchaser's daily quantity of gas used (e.g., 8 AM to
Demand Day 8 AM, etc.). This term is primarily used in pipeline-distribution company
agreements. It is similar to, and usually coincides with, the distribution
company "Contract Day".
The rate of flow of gas required by a consumer or a group of
Demand Load consumers, often an average over a specified short time interval (cf/hr
or Mcf/hr). Demand is the cause; load is the effect.
Page B18 2101510-002 rev. AE

TERM DEFINITION
A device which indicates or records the instantaneous, maximum or
Demand Meters
integrated (over a specified period) demand.
The demand on a system or any of its parts over an interval of time,
Demand, Average determined by dividing the total volume in therms by the number of
units of time in the interval.
Density Mass per unit Volume: D=MV
Doesnt cause the composition of the gas to change, enabling a more
Desaturization
representative sample of gas.
Detector Bead See Thermal Conductivity Detector.
The difference between the value of the controlled variable and the
Deviation
value at which it is being controlled.
The temperature at any given pressure at which liquid initially
condenses from a gas or vapor. It is specifically applied to the
Dew Point temperature at which water vapor starts to condense from a gas
mixture (water dew point) or at which hydrocarbons start to condense
(hydrocarbon dew point).
A glass or metal container made like a vacuum bottle that is used
Dewar
especially for storing liquefied gases. Also called Dewar flask.
DG Display Group. When display group files are created
A bellows inside a displacement type gas meter. Also, a membrane
Diaphragm separating two different pressure areas within a control valve or
regulator.
For an on/off controller, it refers to the temperature difference between
the temperature at which the controller turns heat off and the
Differential
temperature at which the heat is turned back on. It is expressed in
degrees.
A signal-input circuit where SIG LO and SIG HI are electrically floating
with respect to ANALOG GND (METER GND, which is normally tied to
Differential Input DIG GND). This allows the measurement of the voltage difference
between two signals tied to the same ground and provides superior
common-mode noise rejection.
The pressure difference between two points in a system. For example,
Differential Pressure the difference in pressure between the upstream and downstream taps
of an orifice plate, used to measure volume passing through the orifice.
A measure of the display span of a panel meter. By convention, a full
digit can assume any value from 0 through 9, a 1/2-digit will display a 1
Digit and overload at 2, a 3/4-digit will display digits up to 3 and overload at
4, etc. For example, a meter with a display span of 3999 counts is said
to be a 3-3/4 digit meter.
A signal which has distinct states, either on or off (0 or 1). Digital
Digital computers process data as binary information having either true of false
states.
2101510-002 rev. AE Page B19

TERM DEFINITION
The Digital Controller Assembly contains the Digital Electronic Board,
Mounting Assembly and optionally a VGA Display.
Digital Controller The Digital Controller board provides control parameters to the
Assembly Analytical Processor board, stores and processes the data sent from
the Analytical Processor board. The Digital Controller also processes
communication with other devices.
The NGC8200s digital controller assembly provides control parameters
to the analytical processor board, stores and processes the data sent
Digital Controller Assy. from the analytical processor board. The digital controller also
processes communication with other devices. This assembly may also
contain an optional VGA display.
Information transmitted in a coded form (from a computer), represented
Digital Data
by discrete signal elements.
A Microsoft data exchange format generally used to transfer data from
one program to another. It is a very simple format to use and Totalflow
Digital Data Exchange
customers often use TDS to acquire data from Totalflow devices and
or Dynamic Data
then transfer the data to an Excel spreadsheet using DDE. The
Exchange
Totalflow Driver, TDS32, supports DDE and its network version,
NetDDE.
Digital Electronics The branch of electronics dealing with information in binary form.
Digital Input Refers to the signal received in binary format.
Refers to the signal emitted in binary format. An output signal which
Digital Output represents the size of an input in the form of a series of discrete
quantities.
The process of translating discrete data into a continuously varying
Digital to Analog
signal. Common uses are to present the output of a digital computer as
Conversion
a graphic display or as a test stimulus.
Digital-to-Analog An electronic device, often an integrated circuit, that converts a digital
Converter number into a corresponding analog voltage or current.
Deutsches Institut fr Normung. German Institute for Standardization
DIN
set of standards recognized throughout the world.
Rail on which modules are mounted. Allows modules to snap on and
DIN Rail
slide right and left.
Diode A semiconductor that allows current to flow in one direction only.
A bank of switches typically used in setting the hardware configuration
DIP Switches
and base address of an option card.
A current that does not change in direction and is substantially constant
Direct Current
in value.
A method by which information can be transferred from the computer
Direct Memory Access
memory to a device on the bus without using the processor.
The conversion of chemical energy of a cell/battery into electrical
Discharge
energy and withdrawal of the electrical energy into a load.
Page B20 2101510-002 rev. AE

TERM DEFINITION
The rate, usually expressed in amperes, at which electrical current is
Discharge Rate
taken from the cell/battery.
Also called Tubing Manifold. Used in instances when the XFC is not
Discrete Manifold
mounted directly on the Orifice, usually pipe mount or wall mount.
The distillate or middle range of petroleum liquids produced during the
Distillates processing of crude oil. Products include diesel fuel, heating oil,
kerosene and turbine fuel for airplanes.
The first stage in the refining process in which crude oil is heated and
Distillation
unfinished petroleum products are initially separated.
The act or process of distributing gas from the city gas or plant that
portion of utility plant used for the purpose of delivering gas from the
Distribution
city gate or plant to the consumers, or to expenses relating to the
operating and maintenance of distribution plant.
Gas Company which obtains the major portion of its gas operating
revenues from the operation of a retail gas distribution system, and
which operates no transmission system other than incidental
connections within its own system or to the system of another
Distribution Company company. For purposes of A.G.A. statistics, a distribution company
obtains at least 90 percent of its gas operating revenues from sales to
ultimate customers, and classifies at least 90 percent of mains (other
than service pipe) as distribution. Compare INTEGRATED COMPANY;
TRANSMISSION COMPANY, GAS.
Dkt Abbreviation for Dekatherm, equivalent to one MMBtu.
DMM Digital Multi-Meter.
DN Inside diameter standard.
DOS Disk Operating System.
Refers to the DOS version of the Calibration and Collection Unit. Also
DOS CCU
known as FS/2, hand held or Dog Bone.
A group of dots/pixels forming a character or symbol, usually five dots
DOT Matrix
across and seven dots down.
An active element that forms a character or symbol when combined in a
DOT/Pixel
matrix.
This refers to a Totalflow procedure in which any file(s) located on a
laptop PC or storage device, may be copied to the on-board memory of
Download
a Totalflow Host device for purposes of restoring, configuration or
repair.
The oil industry term used to refer to all petroleum activities from the
processing of refining crude oil into petroleum products to the
Downstream
distribution, marketing, and shipping of the products. Also see
Upstream.
Downstream Pipeline The pipeline receiving natural gas at a pipeline inter-connect point.
DP See Differential Pressure.
DRAM See Dynamic Random Access memory.
2101510-002 rev. AE Page B21

TERM DEFINITION
A change of a reading or a set point value over long periods due to
Drift several factors including change in ambient temperature, time, and line
voltage.
Hydrocarbon liquid that separates in a pipeline transporting gas from
Drip Gasoline the well casing, lease separation, or other facilities and drains into
equipment from which the liquid can be removed.
Driver (Hardware) An electronic circuit that provides input to another electronic circuit.
A program that exercises a system or system component by simulating
Driver (Software)
the activity of a higher level component.
Software that controls a specific hardware device, such as interface
Drivers
boards, PLCs, RTUs, and other I/O devices.
Droplet Liquids Large liquid particles
Dry Contact Contacts which neither break nor make a circuit. 0 Ohms.
Has no more than seven pounds of water per million cubic feet of gas.
Gas has less than 0.1 PPM of liquid at the coldest ambient condition
Dry Gas expected at the coldest point in the system. The liquid can be water, oil,
synthetic lubrication, glycol, condensed sample or any other non vapor
contaminate.
DSP Digital Signal Processor.
Dual Element Sensor A sensor assembly with two independent sensing elements.
Memory that can be sequentially accessed by more than one controller
Dual-Access Memory or processor but not simultaneously accessed. Also known as shared
memory.
The ability to both send and receive data simultaneously over the same
Duplex
communications line.
A pair of wires insulated from each other and with an outer jacket of
Duplex Wire
insulation around the inner insulated pair.
The total time to one on/off cycle. Usually refers to the on/off cycle time
Duty Cycle
of a temperature controller.
The Port Manager and communication engine of the SCADAvantage
System. This software can multiplex among several communication
formats and thus supporting several vendors equipment over a single
radio frequency. It pushes new data to the SCADA database, saving
DVI
time and network resources by not transmitting redundant data. The
DVI includes the Totalflow WinCPC code and thus supports all
Totalflow software and functions including WinCCU, TDS, PCCU,
Report by exception, cryout, etc.
This is the most common form of computer memory It needs to be
Dynamic Random
continually refreshed in order to properly hold data, thus the term
Access memory
"dynamic."
See Electrically Erasable Programmable Read-Only Memory. Also
E2Prom
called EEPROM.
Page B22 2101510-002 rev. AE

TERM DEFINITION
Can mean a connection to the earth itself or the negative lead to the
Earth
chassis or any point to zero voltage.
EC European Community.
To reflect received data to the sender. i.e. depressed on a keyboard
Echo
are usually echoed as characters displayed on the screen.
Edit Making changes to information, data or configuration files.
See Electrically Erasable Programmable Read-Only Memory. The
EEPROM
PROM can be erased by electricity.
EFI Electromechanical Frequency Interface.
EFM See Electronic Flow Measurement.
EFR Enhance Feature Release.
Electrical noise induced upon the signal wires that obscures the wanted
Electrical Interference
information signal.
ROM that can be erased with an electrical signal and reprogrammed.
Also referred to as the S Drive. It is a persistent drive that will not loose
Electrically Erasable
its memory unless manually reprogrammed. Also called E2Prom.
Programmable Read-
Totalflows XFC and XRC have a Serial EEPROM on board, which
Only Memory
generally holds registry, application configuration and warranty
information (non-volatile).
The site, area, or location at which electrochemical processes take
Electrode
place.
Term used for European Unions New Approach Directive 89/336/EEC
Electromagnetic which means the device or system is able to function in its
Compatibility electromagnetic environment without introducing intolerable
electromagnetic disturbances to anything in that environment.
Any electromagnetic disturbance that interrupts, obstructs, or otherwise
degrades or limits the effective performance of electronics/electrical
Electromagnetic
equipment. It can be induced intentionally, as in some forms of
Interference
electronic warfare, or unintentionally, as a result of spurious emissions
and responses, intermodulation products, and the like.
Historically, flow measurement was tracked using a chart recording
technology. Developments in the field of electronics allowed for
electronic measurement devices to overtake the chart recording
Electronic Flow
market. This field continues to develop into peripheral markets, making
Measurement
the Flow Meter a valuable asset with multi-tasking Control
capabilities. Totalflows answer to this developing market is the XSeries
equipment.
EMC See Electromagnetic Compatibility
EMI See Electromagnetic Interference.
Emitter One terminal of a transistor.
EN Euro Norm (European Standard)
Enagas Spains Certification Board
2101510-002 rev. AE Page B23

TERM DEFINITION
A device that converts linear or rotary displacement into digital or pulse
signals. The most popular type of encoder is the optical encoder, which
Encoder
uses a rotating disk with alternating opaque areas, a light source, and a
photodetector.
Environmental All conditions in which a transducer may be exposed during shipping,
Conditions storage, handling, and operation.
A liquefiable hydrocarbon product consisting primarily of ethane and
EP Mix
propane.
See Erasable Programmable Read-Only Memory. The PROM can be
EPROM
erased by ultraviolet light or electricity.
ROM that can be erased using Ultraviolet Light. The EPROM maybe re-
Erasable Programmable
programmed by removing the EPROM from the circuit and using
Read-Only Memory
special equipment to write to it.
A colorless hydrocarbon gas of slight odor having a gross heating value
Ethane (C2H6) of 1,773 Btu per cubic foot and a specific gravity of 1.0488. It is a
normal constituent of natural gas.
A colorless unsaturated hydrocarbon gas of slight odor having a gross
heating value of 1,604 Btu per cubic foot and a specific gravity of
Ethylene (C2H4)
0.9740. It is usually present in manufactured gas, constituting one of its
elements and is very flammable.
European Union. Formerly known as the European Community (EC).
Members of this union are replacing individual national regulations of
member countries with a series of Directives. These Directives are
EU legislative instruments which oblige member states to introduce them
into their existing laws. These directives harmonize a variety of existing
practices, preserve the different legal traditions and settle constraints
for further developments.
Important incident: an occurrence, especially one that is particularly
Event
significant.
Stored records specifying a notable change. The XFC stores up to 200
Event File
records, containing: Time, Day, Description, Old Value, New Value.
Signals or interrupts generated by a device to notify another device of
Events
an asynchronous event. The contents of events are device-dependent.
Ex Potential Explosive.
EXIMV Explosion Proof Integral Multivariable Transducer.
A plug-in circuit board that adds features or capabilities beyond those
Expansion Board basic to a computer, such as a data acquisition system expansion
board.
Correction factor for the change in density between two pressure
Expansion Factor
measurement areas in a constricted flow.
The spaces provided in a computer for expansion boards than enhance
Expansion Slots
the basic operation of the computer.
Page B24 2101510-002 rev. AE

TERM DEFINITION
Explosion Proof Enclosure for Class 1 Division 1 locations. An
enclosure that can withstand an explosion of gases within it and
Explosion-proof
prevent the explosion of gases surrounding it due to sparks, flashes or
Enclosure
the explosion of the container itself, and maintain an external
temperature which will not ignite the surrounding gases.
Extended Binary Coded
EBCDIC. An eight-bit character code used primarily in IBM equipment.
Decimal Interchange
The code allows for 256 different bit patterns.
Code
Multivariable Transducer located outside of the Flow Computer
External Multivariable
enclosure. Used in multi-tube configurations and on systems where the
Transducer
actual Flow Computer is located at a distance from the flowing tube.
DP/SP Transducer located outside the enclosure. All electronics are
External Transducer
located inside the enclosure and communicate via a ribbon cable.
Abbreviation of free on board with the cost of delivery to a port and
F.O.B.
loading onto a ship included.
Fa Orifice Thermal Expansion factor.
A temperature scale defined by 32 at the ice point and 212 at the
Fahrenheit
boiling point of water at sea level.
Faux Full Well Stream Factor.
Fb Basic Orifice factor.
FBD Function Block Diagram (IEC supported programming language)
FCC Federal Communications Commission.
FCU Flow computer unit
Feed Points Connections between gas feeder lines and distribution networks.
Occurs when some or all of the output of the device (such as an
amplifier) is taken back to the input. This may be accidental (such as
Feedback
the acoustic feedback from a speaker to microphone) or intentional , to
reduce distortion.
A gas main or supply line that delivers gas from a city gate station or
Feeder (Main)
other source of supply to the distribution networks.
The Feed-Through Assembly also serves as the connection for sample
Feed-Through Assembly streams, carrier gas and calibration streams, and contains the vents for
sample and column gases.
Independent process streams are connected to the NGC8200 directly
through the feed-through assembly or through an optionally installed
Feed-through Assy. sample conditioning system. The feed-through assembly also serves as
the connection for carrier gas and calibration streams and contains the
vents for sample and column gases.
Field-effect transistor. Transistor with electric field controlling output: a
FET transistor, with three or more electrodes, in which the output current is
controlled by a variable electric field.
Fg Specific Gravity factor.
2101510-002 rev. AE Page B25

TERM DEFINITION
The pressure of natural gas as it is found in the underground
Field Pressure
formations from which it is produced.
File A set of related records or data treated as a unit.
Aerosols liquids who have contacted each other and become adhered
Film Liquids
to the inside of the pipeline.
A computer program or software stored permanently in PROM or ROM
Firmware
or semi-permanently in EPROM.
Firmware Version This refers to the version of firmware contained in the equipment.
Fixed-Point A format for processing or storing numbers as digital integers.
Any of various types of indicators used for identification of a condition
Flag or event; for example, a character that signals the termination of a
transmission.
Enclosure which can withstand the pressure developed during an
Flameproof Enclosure internal explosion of an explosive mixture, and which prevents the
d transmission of the explosion to the explosive atmosphere surrounding
the enclosure.
A liquid as defined by NFPD and DOT as having a flash point below
Flammable
37.8C (100F).
For pipe, a metal collar drilled with bolt holes and attached to the pipe
Flange with its flat surface at right angles to the pipe axis so that it can be
securely bolted to a mating flange on a valve, another pipe section, etc.
Re-programmable memory onboard an XFC/XRC, similar to an
EPROM, except that it can be programmed while in circuit using a Boot
FLASH
Loader Program to write to it. Generally used for the operating system
and application code space (non-volatile).
An Analog to Digital Converter whose output code is determined in a
Flash ADC
single step by a bank of comparators and encoding logic.
The temperature at which a liquid will yield enough flammable vapor to
Flash Point ignite. There are various recognized industrial testing methods;
therefore the method used must be stated.
Gas vapors released from a stream of natural gas liquids as a result of
Flash Vapors
an increase in temperature or a decrease in pressure.
Travel of liquids or gases in response to a force (i.e. pressure or
Flow
gravity).
A device placed on location to measure SP, DP and temperature (to
Flow Computer, XSeries calculate flow) of gases or liquids being transferred, for remote
unattended operation.
In the gas industry, formulas used to determine gas flow rates or
Flow Formulas
pressure drops in pipelines, regulators, valves, meters, etc.
Flow Rate Actual speed or velocity of fluid movement .
Flowmeter A device used for measuring the flow or quantity of a moving fluid.
Page B26 2101510-002 rev. AE

TERM DEFINITION
Fluids Substances that flow freely; gases and liquids.
Factory Mutual Research Corporation. An organization which sets
FM
industrial safety standards.
An instrument that meets a specific set of specifications established by
FM Approved
Factory Mutual Research Corporation.
Font The style of lettering used to display information.
Footprint The surface space required for an object.
Fpb Pressure Base factor.
FPM Flow velocity in feet per minute.
FPS Flow velocity in feet per second.
Fpv See Supercompressibility Factor.
Fr Reynolds Number factor.
The process of separating a steam of natural gas liquids into its
Fractionation
separate components.
The temperature at which the substance goes from the liquid phase to
Freezing Point
the solid phase.
The number of cycles per second for any periodic waveform -
measured in cycles per second - now called Hertz. The number of
Frequency
repeating corresponding points on a wave that pass a given
observation point per unit time.
Modulation where the frequency of the sine wave carrier alters with the
Frequency Modulation
amplitude of the modulating signal.
An output in the form of frequency which varies as a function of the
Frequency Output
applied input.
A small fine filter used primarily on the NGC8200 product line in the
Frit Filter feed-through assembly as a last stage gas filter. This filter is not
designed to replace an appropriate sample conditioning system.
Fiberglass Reinforced Polyurethane. A non-flexible material used for
FRP
LevelMaster sensors.
Ruggadized handheld computer device for programming and collecting
FS/2
data from an XFC. Also referred to a Husky or Dog Bone.
FT3 A standard abbreviation for Cubic Foot.
Ftb Temperature Base factor.
Ftf Flowing Temperature factor.
The heavy distillates from the oil refining process that are used
Fuel Oils primarily for heating, for fueling industrial processes, for fueling
locomotives and ships, and for fueling power generation systems.
Wheatstone bridge configuration utilizing four active elements or strain
Full Bridge
gauges.
2101510-002 rev. AE Page B27

TERM DEFINITION
Full Duplex Simultaneous, two-way (transmit and receive), transmission.
A set of software instructions executed by a single line of code that may
Function have input and/or output parameters and returns a value when
executed.
A short length of wire that will easily burn out when excessive current
Fuse
flows.
Fw Water Vapor factor.
G The symbol used for giga or gigabyte.
Gain The factor by which a signal is amplified, sometimes expressed in dB.
Gain Accuracy A measure of deviation of the gain of an amplifier from the ideal gain.
Gal An abbreviation for one gallon.
That state of matter which has neither independent shape nor volume.
Gas It expands to fill the entire container in which it is held. It is one of the
three forms of matter, the other two being solid and liquid.
An analytical instrument that separates mixtures of gas into identifiable
Gas Chromatograph
components by means of chromatography.
Gas Chromatograph Software module used in conjunction with PCCU32 and WINCCU to
Module interact with Btu Chromatograph equipment and software.
Gas Chromatograph A co-efficient generated by the factory allowing user to start calibration
Module Coefficient on location without having a calibration gas available.
Gas Chromatography Preferred method for determining the Btu value of natural gas.
Gas Field A district or area from which natural gas is produced.
An enhanced recovery technique in which natural gas is injected under
Gas Injection pressure into a producing reservoir through an injection well to drive oil
to the well bore and the surface.
The separation of components by absorption, adsorption, refrigeration
or cryogenics from a stream of natural gas for the purpose of making
Gas Processing
salable liquid products and for treating the residue gas to meet required
specifications.
The hydrogen sulfide and/or carbon dioxide contained in, or extracted
Gas, Acid
from, gas or other streams.
Gas produced in association with oil, or from a gas cap overlying and in
contact with the crude oil in the reservoir. In general, most states
restrict associated gas production since its indiscriminate production
Gas, Associated could reduce the ultimate oil recovery. Also, since some wells
producing associated gas cannot be shut-in without also shutting-in the
oil production, natural gas pipelines are generally required to take
associated gas produced from oil wells on a priority basis.
Gas, C1 See Methane.
Gas, C2 See Ethane.
Gas, C3 See Propane.
Page B28 2101510-002 rev. AE

TERM DEFINITION
Gas, C5+ Pentanes Plus (IC5, NeoC5, NC5 and C6+)
Gas, C6+ Hexanes Plus (C6, C7, C8, C9, C10, C11, etc.).
Gas, CO2 See Carbon Dioxide.
Gas whose water content has been reduced by a dehydration process.
Gas containing little or no hydrocarbons commercially recoverable as
Gas, Dry
liquid product. Specified small quantities of liquids are permitted by
varying statutory definitions in certain states.
Gas, IC4 See Iso-Butane.
Gas, IC5 See Iso-Pentane.
A gas containing certain specific hydrocarbons which are gaseous
Gas, Liquefied under normal atmospheric conditions but can be liquefied under
Petroleum (LPG) moderate pressure at normal temperatures. Propane and butane are
the principal examples.
A gas obtained by destructive distillation of coal, or by the thermal
decomposition of oil, or by the reaction of steam passing through a bed
Gas, Manufactured of heated coal or coke, or catalyst beds. Examples are coal gases,
coke oven gases, producer gas, blast furnace gas, blue (water) gas,
and carbureted water gas. Btu content varies widely.
A naturally occurring mixture of hydrocarbon and non-hydrocarbon
gases found in porous geologic formations beneath the earth's surface,
Gas, Natural
often in association with petroleum. The principal constituent is
methane.
Gas, NC4 See Normal Butane.
Gas, NC5 See Normal Pentane.
Gas, NeoC5 See Neo-Pentane.
Free natural gas not in contact with, nor dissolved in, crude oil in the
Gas, Non-associated
reservoir.
A gas resulting from the thermal decomposition of petroleum oils,
composed mainly of volatile hydrocarbons and hydrogen. The true
Gas, Oil
heating value of oil gas may vary between 800 and 1600 Btu per cubic
foot depending on operating conditions and feedstock properties.
Gas found in its natural state, containing such amounts of compounds
Gas, Sour of sulfur as to make it impractical to use, without purifying, because of
its corrosive effect on piping and equipment.
Gas found in its natural state, containing such small amounts of
Gas, Sweet compounds of sulfur that it can be used without purifying, with no
deleterious effect on piping and equipment.
Gas, Unconventional Gas that can not be economically produced using current technology.
Wet natural gas is unprocessed natural gas or partially processed
natural gas produced from strata containing condensable
Gas, Wet
hydrocarbons. The term is subject to varying legal definitions as
specified by certain state statutes.
2101510-002 rev. AE Page B29

TERM DEFINITION
Generally a location at which gas changes ownership, from one party to
another, neither of which is the ultimate consumer. It should be noted,
Gate Station however, that the gas may change from one system to another at this
point without changing ownership. Also referred to as city gate station,
town border station, or delivery point.
The act of operating extensive low-pressure gas lines which aggregate
Gathering the production of several separate gas wells into one larger receipt
point into an interstate pipeline.
Agreement between a producer and a gathering system operator
Gathering Agreement specifying the terms and conditions for entry of the producer's gas into
the gathering system.
A pipeline, usually of small diameter, used in gathering gas from the
Gathering Line
field to a central point.
A compressor station at which gas is gathered from wells by means of
Gathering Station suction because pressure is not sufficient to produce the desired rate of
flow into a transmission or distribution system.
The gathering pipelines plus any pumps, tanks, or additional equipment
Gathering System used to move oil or gas from the wellhead to the main pipeline for
delivery to a processing facility or consumer.
A measure of the ratio of the relative change of resistance to the
Gauge Factor
relative change in length of a piezoresistive strain gage.
Gauge Pressure Absolute pressure minus local atmospheric pressure.
Instrument for measuring the relative pressure of a fluid. Types include
Gauge, Pressure
gauge, absolute, and differential.
Gauging Tape This refers to a manual method of measuring the level of a liquid in a
Measurements tank. These measurements may be used to calibrate float levels.
GC See Gas Chromatograph.
The NGC8200s GC module is comprised of three parts: columns,
chromatographic valve and GC module circuit board. The valve controls
the flow of gas within the system. The columns perform the separation
of the gas into component parts for analysis. The GC module circuit
board contains the sensors for the carrier pressure regulators, the
GC Module
sample pressure sensor and the thermal conductivity detectors (TCD's)
which detect the different gas components as they leave the GC
columns. It also contains an EEPROM or FLASH memory for storage of
calibration and characterization information of the module and its
sensors.
The GC Module is comprised of 3 parts; Columns, Valves and
Electronic Interface. The Valves control flow of gas within the system.
The Columns perform the separation of the gas into component parts
GC Module Assembly
for analysis. The Electronic Interface contains pressure and
temperature sensors to monitor and detect the different gas
components as they leave the GC Columns.
GCM See Gas Chromatograph Module
Page B30 2101510-002 rev. AE

TERM DEFINITION
GCM See Gas Chromatograph Module Coefficient.
Gravity, Carbon Dioxide and Nitrogen compounds. Used in NX-19 GCN
GCN
Supercompressibility Factor.
Gravity, Carbon Dioxide, Nitrogen and Methane compounds. Used in
GCNM
NX-19 GCNM Supercompressibility Factor.
GDF Gasde of France
An abbreviation for gigajoule, equivalent to one thousand mega joules
Gj
or one billion joules.
GND See Ground.
GOST Russian Government Standards for Importation.
Gas Processors Association Physical Constants for Paraffin
GPA 2145-03
Hydrocarbons and other Components of Natural Gas
Gas Processors Association Calculation of Gross Heating Value,
GPA 2172-96 Relative Density and Compressibility of Natural Gas Mixtures from
Compositional Analysis.
GPM Gallons of liquid per thousand cubic feet.
GPS 2261 See Gas Processors Standard 2261.
Gauge Port Vent. Refers to the NGC8200 Port designed to equalize the
GPV
pressure inside of the explosion-proof enclosure.
Gauge Port Valve (located on NGC8200 series Feed-Through
GPV
Assembly).
GRD See Ground.
The heating value measured in a calorimeter when the water produced
Gross Heating Value during the combustion process is condensed to a liquid state. The heat
of condensation of the water is included in the total measured heat.
1) An electronically neutral circuit having the same potential as the
surrounding earth. Normally, a non-current carrying circuit intended for
the safety purposes. A reference point for an electrical system. 2) A
Ground
large conducting body (as the earth) used as a common return for an
electric circuit and as an arbitrary zero of potential. 3) Reference point
for an electrical system.
A grounding strap is a conductive device used to make connection
Grounding Strap between the person handling the board, and a high quality ground
potential.
H2 The molecular formula for Hydrogen.
H2S The molecular formula for Hydrogen Sulfide.
Half Duplex Communication transmission in one direction at a time.
An interface procedure that is based on status/data signals that assure
Handshake
orderly data transfer as opposed to asynchronous exchange.
2101510-002 rev. AE Page B31

TERM DEFINITION
Exchange of predetermined signals between two devices establishing a
Handshaking
connection. Usually part of a communications protocol.
The physical components of a computer system, such as the circuit
Hardware boards, plug-in boards, chassis, enclosures, peripherals, cables, and so
on. It does not include data or computer programs.
A sinusoidal component of a waveform that is a whole multiple of the
Harmonic fundamental frequency. An oscillation that is an integral sub-multiple of
the fundamental is called a sub-harmonic.
HART Communication Interface.
Area in which an explosive gas atmosphere is present or may be
Hazardous Area
expected to be present.
Heat Thermal energy. Heat is expressed in units of calories or Btu's
The amount of heat required to raise the temperature of a body (of any
Heat Capacity
mass) one degree Celsius.
The amount of heat that must be removed from one gram of a vapor at
Heat of Condensation it's condensation point to condense the vapor with no change in
temperature.
The amount of heat required to vaporize one gram of a liquid at its
boiling point with no change in temperature. Usually expressed in J/g.
Heat of Vaporization The molar heat of vaporization is the amount of heat required to
vaporize one mole of liquid at its boiling point with no change in
temperature and usually expressed ion kJ/mol.
A form of energy that flows between two samples of matter because of
Heat Transfer
their differences in temperature.
The amount of heat developed by the complete combustion of a unit
quantity of a material. Heating values for natural gas are usually
Heating Value expressed as the Btu per Cf of gas at designated conditions
(temperature and pressure) and either on the dry or water saturated
basis.
Heavy Crude Crude oil of 20-degree API gravity or less; often very thick and viscous.
The portion of a hydrocarbon mixture having the highest boiling point.
Heavy Ends Hexanes or heptanes and all heavier hydrocarbons are usually the
heavy ends in a natural gas stream.
More susceptible to increases in temperature and decreases in
Heavy Hydrocarbons
pressure, thus causing liquids to form.
A saturated hydrocarbon (Alkane) with 7 carbon atoms in its molecule
Heptane (C7H16)
(C7H16). A liquid under normal conditions.
Hertz Cycles per second. A measure of frequency or bandwidth.
Hexadecimal A numbering system to the base 16, 0 through F.
A saturated hydrocarbon (Alkane) with six carbon atoms in its molecule
Hexane (C6H14)
(C6H14). A liquid under normal conditions.
Page B32 2101510-002 rev. AE

TERM DEFINITION
The portion of a hydrocarbon fluid mixture or the last component of a
Hexane Plus or Heptane
hydrocarbon analysis which contains the hexanes (or heptanes) and all
Plus
hydrocarbons heavier than the hexanes (or heptanes).
A method of organizing computer programs with a series of levels, each
Hierarchical
with further subdivisions, as in a pyramid or tree structure.
Meter HOLD is an external input which is used to stop the A/D process
Hold and freeze the display. BCD HOLD is an external input used to freeze
the BCD output while allowing the A/D process to continue operation.
Host The primary or controlling computer in a multiple part system.
Host Console via Local Port uses the PCCU cable between the
Host Console computer and the devices Local PCCU port but running Remote
Protocol. Host Console via Remote Port uses the remote protocol
A market or supply area pooling/delivery where gas supply transaction
point occur that serve to facilitate the movement of gas between and
Hub
among interstate pipelines. Transactions can include a change in title, a
change in transporter, or other similar items.
HV See Heating Value.
A chemical compound composed solely of carbon and hydrogen. The
compounds having a small number of carbon and hydrogen atoms in
Hydrocarbon their molecules are usually gaseous; those with a larger number of
atoms are liquid, and the compounds with the largest number of atoms
are solid.
A flammable, very poisonous and corrosive gas with a markedly
Hydrogen Sulfide disagreeable odor, having the chemical formula of H2S that is a
contaminant in natural gas and natural gas liquids.
Hyper term Terminal emulation program provided with Windows.
The maximum difference between output readings for the same
measured point, one point obtained while increasing from zero and the
Hysteresis other while decreasing from full scale. The points are taken on the
same continuous cycle. The deviation is expressed as a percent of full
scale.
I/O See Input/Output.
A method that allows the CPU to distinguish between the different
I/O Address
boards in a system. All boards must have different addresses.
Inter-Integrated Circuit. Serial communications bus to I/O modules
I2C
(developed by Phillips Semiconductor)
Maker and distributor of the Embedded Workbench, a compiler,
IAR assembler, linker development system for the Z80/64180
microprocessor family.
IC See Integrated Circuit
IC4 A standard abbreviation for Isobutane.
IC5 A standard abbreviation for Isopentane.
2101510-002 rev. AE Page B33

TERM DEFINITION
A graphic functional symbol display. A graphic representation of a
Icon
function or functions to be performed by the computer.
Identification Number. You must assign an ID to the unit. Units are
ID communicated to by this ID number, therefore the ID assigned in the
software must agree with the hardware.
International Electrotechnical Commission. Developers of the IEC-
IEC 61131-3 standard. Programming Language used by Totalflow for user
applications in XSeries equipment.
The IEC scheme for certification to standards relating to equipment for
IECEx
use in explosive atmospheres.
IEEE Institute of Electrical and Electronics Engineers
IIC Inter-Integrated Circuit. Also see I2C.
IL Instruction List (IEC supported programming language)
Impedance The total opposition to electrical flow (resistive plus reactive).
IMV See Integral Multivariable Transducer.
A pressure unit representing the pressure required to support a column
of mercury one inch high at a specified temperature; 2.036 inches of
Inch of Mercury
mercury (at 32 degrees F and standard gravity of 32.174 ft/sec2) is
equal to a gauge pressure of one pound per square inch.
A pressure unit representing the pressure required to support a column
of water one inch high. Usually reported as inches W.C. (water column)
Inch of Water at a specified temperature; 27.707 inches of water (at 60o and standard
gravity of 32.174 ft/sec2) is equal to a gauge pressure of one pound per
square inch.
Industry Canada Canadian Certification.
Elements or compounds not acted upon chemically by the surrounding
environment. Nitrogen and carbon dioxide are examples of inert
Inerts
components in natural gas. Inerts dilute the natural gas and since they
do not burn or combust, have no heating value.
Generic file used to support the display of Totalflow application data in
Initialization File
PCCU32.
Input That part of a circuit that accepts a signal for processing.
The resistance measured across the excitation terminals of a
Input Impedance
transducer.
Input Sense To examine or determine the status of the input.
The transfer of data to/from a computer system involving
Input/Output communications channels, operator interface devices, and/or data
acquisition and control interfaces.
Instantiate Starting an instance of an object.
Instrument Manifold Manifold type used when XFC is mounted directly on the Orifice.
Insulator Any material that resists the flow of electrical current.
Page B34 2101510-002 rev. AE

TERM DEFINITION
A Multivariable Transducer that is an integral part of the flow computer,
measuring DP and SP. This refers only to the transducer portion of the
Integral Multivariable
device and makes no assumption whether or not the circuitry is located
Transducer
as part of the unit, or if the circuitry is located on the Mother Board and
attached via wiring. Also see Multivariable Transducer.
A circuit component consisting of a piece of semiconductor material
Integrated Circuit
containing up to thousands of transistor and diodes. A chip.
An ADC whose output code represents the average value of the input
Integrating ADC
voltage over a given time interval.
Usually refers to the hardware that provides communication between
Interface (computer)
various items of equipment.
The area between two liquids that are not easily mixed, i.e. oil and
Interface (liquid)
water.
Interference A disturbance to the signal in any communications system.
An instrument which will not produce any spark or thermal effects under
Intrinsically Safe normal and specified fault conditions, that is capable of causing ignition
of a specified gas mixture.
A circuit in both analogue and digital systems that provides an output
Inverter
that is inverse to the input.
Inverter, DC to AC Converts DC to AC at a high frequency.
ioINT Interrupt signal from the I/O modules.
i/o Battery Voltage- Unregulated 13.8 volts. Host supplies 2.5 amps to
ioVBB
the I/O modules.
ioVDD Unregulated 5.6 volts from the host for I/O modules.
ISA Instrument Society of America.
ISO International Standards Organization.
International Standards Organization Report No. 5167, Measurement of
ISO 5167
Fluid Flow by Means of Pressure Differential Devices.
International Standards Organization Report No. 6976-95, Calculation
ISO 6976-95 of Calorific Values, Density, Relative Density and Wobbe Index from
Composition.
A hydrocarbon of the same chemical formula as butane but different
Isobutane (C4H10) molecular structure, resulting in different physical properties, notably
lower boiling point. Gross heating value 3261 Btu/cu. ft. gas.
Laboratory technique where gas sample is tested after removing
Isokenetic Sampling liquids, therefore not allowing the atomized liquid to return to the
gaseous state, changing the sample accuracy.
The reduction of the capacity of a system to respond to an external
Isolation
force by use of resilient isolating materials.
A hydrocarbon of the paraffin series having a chemical formula of
Isopentane (C5H12)
C5H12 and having its carbon atoms branched.
2101510-002 rev. AE Page B35

TERM DEFINITION
Acronym for International Union of Pure and Applied Chemistry. It is an
international non-governmental organization devoted to the
IUPAC advancement of chemistry. It is most well known as the recognized
authority in developing standards for the naming of the chemical
elements and their compounds
Joule The basic unit of thermal energy.
The change in gas temperature which occurs when the gas is
expanded at constant enthalpy from a higher pressure to a lower
Joule-Thompson Effect
pressure. The effect for most gases at normal pressure, except
hydrogen and helium, is a cooling of the gas creating condensation.
Kilo. 1) In referring to computers, a "kilo" is 1024 or 2 to the 10th power
(Note that it is actually slightly more than an even 1000.). 2) the
K
standard metric prefix for 1,000, or 103, used with units of measure
such as volts, hertz, and meters.
Kbytes/s A unit for data transfer that means 1,000 or 103 bytes/s.
An oily liquid obtained in the distilling of gasoline in a temperature
range from 174-288 degree C. A hydrocarbon of specific gravity of
Kerosene 0.747 to 0.775. Used as fuel for some internal combustion engines,
heating equipment, and illuminating purposes. A heavy grade known as
range oil is used for cooking and heating.
KHz Electronic abbreviation for Kilohertz.
kilobyte 1024 bytes.
Kilowatt Equivalent to 1000 watts.
A unit of energy when one kilowatt of power is expended for one hour.
kilowatt-hour Example A radiator bar is usually rated at 1,000 watts and this switched
on for one hour consumes one kilowatt-hour of electricity.
KPa Kilopascal-Measure of Pressure
kw See Kilowatt.
kwh See Kilowatt-hour.
LACT Lease Automatic Custody Transfer.
1) A time delay between the output of a signal and the response of the
instrument to which the signal is sent. 2) A time relationship between
Lag
two waveforms where a fixed reference point on one wave occurs after
the same point of the reference wave.
Represents the amount of heat required to vaporize a liquid. In the
Latent Heat of
instance of natural gas, the equation appears: 1 Btu = heat to change.
Vaporization
This is the most likely scenario for causing gas to liquefy.
LCD Liquid Crystal Display.
LD Ladder Diagram (IEC supported programming language)
LED Light Emitting Diodes.
Page B36 2101510-002 rev. AE

TERM DEFINITION
Intelligent Digital Level Sensor and is designed for custody transfer
LevelMaster accuracy in demanding level measurement applications in tanks.
LevelMaster is the name of the Totalflows Tank Gauging System.
For rechargeable batteries, the duration of satisfactory performance,
Life measured in years (float life) or in the number of charge/discharge
cycles (cycle life).
The minimum number of pressure cycles the transducer can endure
Life Cycle
and still remain within a specified tolerance.
Crude oil with a high API gravity due to the presence of a high
Light Crude
proportion of light hydrocarbon fractions.
The portion of a liquid hydrocarbon mixture having the lowest boiling
Light Ends
points which are easily evaporated.
The low molecular weight hydrocarbons such as methane, ethane,
Light Hydrocarbons
propane and butanes. More Volatile.
The maximum deviation of the calibration curve from a straight line
Linearity between zero and full scale, expressed as a percent of full scale output
and measured on increasing measurement only.
Liquefiable The components of natural gas that may be recovered as liquid
Hydrocarbons products.
Natural gas which has been liquefied by reducing its temperature to
minus 260 degrees Fahrenheit at atmospheric pressure. It remains a
Liquefied Natural Gas liquid at -116 degrees Fahrenheit and 673 psig. In volume, it occupies
1/600 of that of the vapor at standard conditions. Natural gasoline and
liquefied petroleum gases fall in this category.
A gas containing certain specific hydrocarbons which are gaseous
under normal atmospheric conditions, but can be liquefied under
Liquefied Petroleum Gas
moderate pressure at normal temperatures. Propane and butane are
the principal examples.
Liquid Crystal Display A reflective display that requires very low power for operation.
LNG See Liquefied Natural Gas.
A load is an energy consuming device. The device can be an actual
Load (electrical) device such as a bulb of a flash light, radio, cassette player, motor, etc.,
a resistor or a constant current load.
The amount of gas delivered or required at any specified point or points
on a system; load originates primarily at the gas consuming equipment
Load (units) of the customers. Also, to load a pressure regulator is to set the
regulator to maintain a given pressure as the rate of gas flow through
the regulator varies. Compare DEMAND.
This is a file containing the configuration of the Location or site and the
LevelMasters assigned to the Location. You may have a file that
Location File contains everything or a file for each Location name. The information
from the file is displayed on the main MasterLink screen in the form of a
tree structure. See the Main Screen topic for more information.
2101510-002 rev. AE Page B37

TERM DEFINITION
Location Name is the top of the hierarchy tree of a Location File.
Location Name Included in the Location Name is the LevelMaster's name, ID, S/N,
Sensor File and Configuration no.
In a XFC, the specified length between writing the calculated
accumulated volume to record. You may record volumes as often as
Log Period
every minute and as seldom as every hour. More frequent recording
reduces the number of days of records possible between collection.
For Totalflows purpose, the application of this term refers to storing
data over a period of time that is greater than a minimal time. Such as
Long Term
data collected weekly versus data collected weekly but stored
indefinitely.
LPG See Liquefied Petroleum Gas.
LSB Least Significant Byte
Mega, the prefix for 1,048,576, or 220, when used with byte to quantify
M
data or computer memory. Also 1000, as in MCF or 1000 Cubic Ft.
The conduit of an appliance which supplies gas to the individual
Manifold
burners. Also, a pipe to which two or more outlet pipes are connected.
The Manifold Assembly is comprised of the Manifold Plate, Heater,
Valves, and various Cables to other major components. The Manifold
Plate and Heater maintain constant temperature for the GC Module and
Manifold Assembly Columns. The Valves control Stream processing, Carrier and
Calibrations gases. The Cables complete the information chain from the
GC Module to the Analytical Processor and the Digital Controller
Assembly.
Software program that converts machine instructions and commands
Man-Machine Interface
into a user interface.
Manometer A two-armed barometer.
The switch in a limit controller that manually resets the controller after
Manual Reset
the limit has been exceeded.
MasterLink is the name of the software program used to communicate
with the LevelMaster for purposes of doing setup, calibration,
MasterLink
troubleshooting, generating site files, monitoring levels and collecting
data.
Mbytes/s A unit for data transfer that means 1 million or 106 bytes/s.
The quantity of natural gas occupying a volume of 1000 cubic feet at a
Mcf
temperature of 60 Fahrenheit and at a pressure of 14.73 psia.
The average of the maximum and minimum temperature of a process
Mean Temperature
equilibrium.
FLOs measurement and operational features are housed in this
Measurement Unit single unit assembly. The main electronic board (FLO-195 Board),
Assembly communication connection, power, SP, DP and Temperature readings
are all housed in this unit.
Mega Multiplier indicating that a quantity should be multiplied by 1,000,000.
Page B38 2101510-002 rev. AE

TERM DEFINITION
The temperature at which a substance transforms from a solid phase to
Melting Point
a liquid phase.
The pH-sensitive glass bulb is the membrane across which the
potential difference due to the formation of double layers with ion-
Membrane exchange properties on the two swollen glass surfaces is developed.
The membrane makes contact with and separates the internal element
and filling solution from the sample solution.
Electronic devices that enable a computer to store and recall
Memory information. In its broadest sense, memory refers to any hardware
capable of serving that end, e.g., disk, tape, or semiconductor storage.
The list of available functions for selection by the operator, usually
Menu
displayed on the computer screen once a program has been entered.
SICK Engineerings Menu-based Measurement and Parameterization
MEPAFLOW
Software for the TotalSonic system (MMI).
Compounds of carbon, hydrogen and sulfur found in sour crude and
Mercaptans gas; the lower mercaptans have a strong, repulsive odor and are used,
among other things, to odorize natural gas.
Meter Acronym M. Metric measurement equal to 1.09361 yards.
Gas piping between gas service line and meter. Also, gas piping
Meter Manifold
supplying two or more meters.
A meter using the differential pressure across an orifice plate as a basis
Meter, Orifice for determining volume flowing through the meter. Ordinarily, the
differential pressure is charted.
Meter, PD See Meter, Positive Displacement.
Meter, Positive An instrument which measures volume on the basis of filling and
Displacement discharging gas in a chamber.
1) Pulse meter. 2)A velocity measuring device in which the flow is
parallel to the rotor axis and the speed of rotation is proportional to the
Meter, Turbine rate of flow. The volume of gas measured is determined by the
revolutions of the rotor and converting them to a continuously totalized
volumetric reading.
A hydrocarbon (Alkane) with the lightest molecule. A gas under normal
conditions. The first of the paraffin series of hydrocarbons. The chief
Methane (C1H4) constituent of natural gas. Pure methane is odorless and has a heating
value of 1012 Btu per cubic foot. Typically mixed with a sulfur
compound to aid in leak detection.
microFlo Computer See FLO.
This term is commonly used to describe the CPU. More specifically, it
Microprocessor refers to the part of the CPU that actually does the work, since many
CPUs now contain L1 and L2 caches on-chip.
One thousandth e.g. one milli-watt - 1mW. one milli-amp - 1mA. one
Milli
milli-volt -1mV.
Millimeter Acronym mm. Metric measurement equal to .03937 inch.
2101510-002 rev. AE Page B39

TERM DEFINITION
Million instructions per second. The unit for expressing the speed of
MIPS
processor machine code instructions.
Mj Abbreviation for mega joule, equivalent to one million joules.
Mm Acronym for Millimeter.
A thermal unit of energy equal to 1,000,000 Btus, that is, the equivalent
MMBtu of 1,000 cubic feet of gas having a heating content of 1,000 BTUs per
cubic foot, as provided by contract measurement terms.
MMcf A million cubic feet. See CUBIC FOOT. (1,000,000 CF)
MMI See Man-Machine Interface.
Messaging structure developed and used to establish master-
Modbus slave/client-server communication between intelligent devices. Generic
protocol supported by most process automation vendors.
Modulator-Demodulator. A device used to convert serial digital data
from a transmitting terminal to a signal suitable for transmission over a
Modem
common carrier, or to reconvert the transmitted signal to digital data for
acceptance by a receiving terminal.
Typically a board assembly and its associated mechanical parts, front
Module panel, optional shields, and so on. A module contains everything
required to occupy one or more slots in a mainframe.
Mol% See Mole Percent.
The number of moles of a component of a mixture divided by the total
Mole Percent
number of moles in the mixture.
Modbus Request Block. When requesting storage space after adding a
MRB
new Modbus application, the file is saved as a *.mrb file.
Modbus Register Map. When requesting storage space after adding a
MRM
new Modbus register, the file is saved as a *.mrm file.
MS Milliseconds. One-thousandth of a second.
MSB Most Significant Byte
A high-accuracy bridge configuration used to measure three-wire RTD
Mueller Bridge
thermometers.
A technique which allows different input (or output) signals to use the
Multiplex same lines at different times, controlled by an external signal.
Multiplexing is used to save on wiring and I/O ports.
A property of an operating system in which several processes can be
Multi-tasking
run simultaneously.
Locations where many flow tubes are all within a prescribed distance
allowing one flow meter with multitube capabilities, such as the XSeries
Multi-tube Sites
product line, to monitor and maintain flow records for each tube in one
Flow Computer.
Page B40 2101510-002 rev. AE

TERM DEFINITION
Transducer supplying more than 1 variable. Totalflow uses this term to
encompass units that read Static Pressure, Differential Pressure.
Historically these units were coined AMU for Analog Measurement Unit.
As a result of advanced technology, the unit no longer functions as only
an analog measurement unit. Therefore the newer terminology,
Multivariable Transducer, more aptly describes the functionality of this
Multivariable Transducer
design. The abbreviation IMV refers to the Integral version of the
multivariable. The abbreviation XIMV, refers to the XSeries IMV version
of the multivariable, which contains the circuitry as part of the unit and
the abbreviation IMVX, refers to the Explosion Proof IMV, where the
required circuitry resides on the Main Processor Board. See each
instance for additional explanation.
MW Acronym for Molecular Weight.
N2 A standard abbreviation for Nitrogen.
NAK See Negative Acknowledgement
Normenarbeitsgemeinschaft fr Mess- und Regeltechnik in der
NAMUR chemischen Industrie (Standards study group for measurement and
process control technology in the chemical industry).
Natural Gas See Gas, Natural.
Material removed from natural gas at the "heavy end" portion; that is,
Natural Gas Distillate
aliphatic compounds ranging from C4 to C8 (butanes and heavier).
The hydrocarbon components: propane, butanes, and pentanes (also
referred to as condensate), or a combination of them that are subject to
recovery from raw gas liquids by processing in field separators,
Natural Gas Liquids
scrubbers, gas processing and reprocessing plants, or cycling plants.
The propane and butane components are often referred to as liquefied
petroleum gases or LPG.
A mixture of hydrocarbons, mostly pentanes and heavier, extracted
Natural Gasoline
from natural gas, which meets vapor pressure and other specifications.
NBS National Bureau of Standards.
NC See Normally Closed.
NC4 A standard abbreviation for Normal Butane.
NC5 A standard abbreviation for Normal Pentane.
NEC National Electrical Codes
This refers to a response over a remote communication device, such as
Negative a PING. Basically, saying, "I dont acknowledge your request!" This is
Acknowledgment the opposite of ACK. NAK is a slang term that means that you disagree
or do not acknowledge something.
NEMA National Electrical Manufacturers Association.
A standard from the National Electrical Manufacturers Association.
Enclosure constructed for indoor/outdoor use to provide protection
NEMA, Type 3R
against falling dirt, rain, sleet and snow and remain undamaged by
external formation of ice.
2101510-002 rev. AE Page B41

TERM DEFINITION
Enclosure constructed for indoor/outdoor use to provide protection
NEMA, Type 4 against falling dirt, rain, sleet, snow, windblown dust, splashing water,
and hose-directed water and remain undamaged by external formation
of ice.
NEMA, Type 4X
Enclosure constructed as for Type 4 with protection against corrosion.
NeoC4 A standard abbreviation for Neobutane.
NeoC5 A standard abbreviation for Neopentane.
A group of computers that are connected to each other by
Network
communications lines to share information and resources.
Newton Meter Torque measurement unit equal to 8.84 Inch Pounds.
NGC Natural Gas Chromatograph
The NGC8200 Termination Panel acts as a connection to the outside
world. It features Transient Protection, a built-in voltage regulator,
Positive Temperature Co-efficient Fuses (PTC) and many other
NGC Termination Panel safeguards to protect the remainder of the system from electrical
damage. All outside communications and I/O are channeled through
this board. It is designed to be a low cost, field replaceable
maintenance solution and is designed to operate on either 12V or 24V.
Totalflow NGC8201 Gas Chromatograph for Process Gas
Chromatography. The NGC is designed to continually analyze process
gas streams, on-site, determine composition, calorific value, and store
NGC8201 the analysis information.
The unit can collect and retain analysis information for one to four
independent sample streams.
Totalflow NGC8200 Gas Chromatograph, with C6+. The NGC is
designed to continually analyze natural gas streams, on-site, determine
composition, calorific value, and store the analysis information. It is
designed for natural gas streams, 800 to 1500 Btu/scf (29.8 to 55.9
Mega joules/meter3) with less than 100 PPM H2S.
NGC8206 The unit is a fully functional gas chromatograph for Pipeline Quality
natural gas, designed to analyze natural gas streams, dry of both
hydrocarbon liquids and water. The unit can collect and retain analysis
information for one to four independent sample streams. Applicable
installations include: Transmission, Distribution, Custody Transfer with
Metrology quality results, Production, Gas Gathering and End User Gas
Markets.
NGL See Natural Gas Liquids.
NGL A standard abbreviation for Natural Gas Liquids.
Nm Abbreviation for Newton Meter. Metric Torque measurement.
NO See Normally Open.
Page B42 2101510-002 rev. AE

TERM DEFINITION
An undesirable electrical signal. Noise comes from external sources
such as the AC power line, motors, generators, transformers,
fluorescent lights, soldering irons, CRT displays, computers, electrical
Noise storms, welders, radio transmitters, and internal sources such as
semiconductors, resistors, and capacitors. Unwanted disturbances
superimposed upon a useful signal that tends to obscure its information
content.
A hydrocarbon (Alkane) flammable colorless liquid with nine carbon
Nonane (C9H20)
atoms.
Area in which an explosive gas atmosphere is not expected to be
Non-hazardous area
present in quantities such as to require special precautions.
Non-Persistent Refers to data that is no longer available after a Warm Start.
An aliphatic compound of the paraffin series having the chemical
Normal Butane formula of C4H10 and having all of its carbon atoms joined in a straight
chain.
A hydrocarbon of the paraffin series having a chemical formula of
Normal Pentane
C5H12 and having all its carbon atoms joined in a straight chain.
The exact amount of sample which is injected onto the columns of the
chromatograph must be a very reproducible volume in order to give
consistent values for the resulting calculated Btu. The calculation
controls the volume, temperature and pressure of the sample to be
injected by a very simple means. A few seconds before the sample is
actually injected, the flow of sample through the sample valve injection
loop is stopped by automatically shutting the sample shut-off valve.
This allows the pressure of the sample in the sample loop to bleed
down to atmospheric pressure. Since the temperature is controlled and
the size of sample loop does not vary then the only change possible in
sample size is related to variations in atmospheric pressure.
Normalization of Atmospheric pressure does vary with the weather and in order to
Component Mole compensate for this or any other slight sample size change, the mole
Percentages percentages of each component are adjusted to equal a total of 100%
through a calculation called normalization.
The values in mole percents are determined by the chromatographic
analysis and then totaled to a value that is near 100%, which is called
the unnormalized total. The unnormalized total is divided by 100% and
the resulting factor is then multiplied by the mole% value for each
component. This calculation will adjust each components mole% in the
correct manner as to result in a new total of exactly 100%. The
calculation also checks to see if the unnormalized total is out of a
specified range for alarm purposes. This is an overall performance
check to determine if the chromatograph has some problem or has
drifted out of calibration.
Designation which states that the contacts of a switch or relay are
Normally Closed closed or connected when at rest. When activated, the contacts open
or separated.
2101510-002 rev. AE Page B43

TERM DEFINITION
Designation which states that the contacts of a switch or relay are
Normally Open normally open or not connected. When activated the contacts close or
become connected.
Norsok Norwegian Certification Bureau
NPN Negative-Positive-Negative (Transistor).
NPT National Pipe Thread.
NRTL Nationally Recognized Testing Laboratory.
A condition, such as balance, which results in a minimum absolute
Null
value of output.
American Gas Association Report referring to a specific method to
NX-19
calculate the Supercompressibility factor.
O2 A standard abbreviation for oxygen.
A hydrocarbon (Alkane) flammable colorless liquid with eight carbon
Octane (C8H18)
atoms. Is the 100 point on the Octane Rating Scale.
OCV See Open Circuit Voltage.
ODBC See Open Database Connectivity.
OEU Optional Equipment Unit.
The difference in temperature between the set point and the actual
Offset
process temperature. Also, referred to as droop.
The unit of resistance usually shown as the symbol "R". One thousand
OHM ohms is written "k" and one million ohms is written "M". Resistance is
measured with a multimeter, set to the "ohms range".
Ohmmeter An instrument used to measure electrical resistance.
Object Linking and Embedding. A set of system services that provides
a means for applications to interact and interoperate. Based on the
underlying Component Object Model, OLE is object-enabling system
software. Through OLE Automation, an application can dynamically
OLE
identify and use the services of other applications, to build powerful
solutions using packaged software. OLE also makes it possible to
create compound documents consisting of multiple sources of
information from different applications.
This is a data interchange format and supporting software. Typically,
vendors (such as ABB) write OPC server drivers which can talk to their
devices. SCADA system vendors (again like ABB) write OPC clients
Ole for Process Control that can gather data from OPC Servers. The idea is to provide a
universal way to collect data into a SCADA system regardless of the
equipment vendor. This standard was developed and is maintained by
the OPC Foundation. The Totalflow Driver, TDS32, supports OPC.
Ole for Process Control
A programming interface to databases. Supports the OLEDB interface.
Database
OLEDB See Ole for Process Control Database.
Page B44 2101510-002 rev. AE

TERM DEFINITION
Basic chemicals made from oil or natural gas liquids feedstocks;
Olefins commonly used to manufacture plastics and gasoline. Examples are
ethylene and propylene.
Object-Oriented Programming. The XFC/XRC architecture incorporates
OOP
an object-oriented approach.
OPC See Ole for Process Control.
Open Circuit A complete break in a metal conductor path.
The difference in potential between the terminals of a cell/battery when
Open Circuit Voltage
the circuit is open (no-load condition).
A single NPN transistor with the base connected to the logic driving
Open Collector circuitry and with the emitter grounded. The collector is the output pin of
the gate.
A widely accepted application-programming interface (API) for
database access. It is based on the Call-Level Interface (CLI)
specifications from X/Open and ISO/IEC for database APIs and uses
Structured Query Language (SQL) as its database access language.
Open Database Using ODBC, you can create database applications with access to any
Connectivity database for which your end-user has an ODBC driver. This allows
access for authorized users to databases over any network, including
the Internet. The SCADA system provides an ODBC driver, making the
database accessible to authorized users anywhere on a corporate
network, or even over the Internet if the network is properly configured.
Base-level software that controls a computer, runs programs, interacts
Operating System with users, and communicates with installed hardware or peripheral
devices.
Totalflow enclosure designed to house optional power and
Optional Equipment Unit
communication devices.
Device to record differential pressure measurement which uses a steel
plate with a calibrated hole or orifice to generate a drop in pressure
Orifice Meter
between the two sides of the plate. Also the primary element of the
meter run.
A plate of non-corrosive material which can be fastened between
flanges or in a special fitting perpendicular to the axis of flow and
Orifice Plate
having a concentric circular hole. The primary use is for the
measurement of gas flow.
Boolean algebra logical function. Described as the addition or summing
of switches or inputs, in the case of Boolean elements, the 0 and 1
represent two possible states of a premise or hypothesis: True or False,
On or Off. When adding Boolean elements not real numbers, you will
ORing find these results:
1 or 1 = 1
1 or 0 = 1
0 or 1 = 1
0 or 0 = 0
O-Ring A flat ring made of rubber or plastic, used as a gasket.
2101510-002 rev. AE Page B45

TERM DEFINITION
Output That part of a circuit where the processed signal is available.
The resistance as measured on the output terminals of a pressure
Output Impedance
transducer.
The RMS, peak-to-peak (as specified) ac component of a transducer's
Output Noise
dc output in the absence of a measurand variation.
P/I See Pulse Input.
(1) Characteristic. For example, specifying parameters means defining
the characteristics of something. In general, parameters are used to
customize a program. For example, file names, page lengths, and font
Parameter
specifications could all be considered parameters. (2) In programming,
the term parameter is synonymous with argument, a value that is
passed to a routine.
A technique for testing transmitting data. Typically, a binary digit is
Parity added to the data to make the sum of all the digits of the binary data
either always even (even parity) or always odd (odd parity).
Parts per Million Acronym PPM.
Passive Analog Output Analog Output to a host that is powered by an outside source.
PCCU Portable Collection and Calibration Unit.
Windows version of PCCU communications software to process,
PCCU32 archive and collect data from the Totalflow equipment. Generally run
from a laptop.
The retention time the element takes to exit the column. This is used in
Peak Area
calculating the amount of each component in the sample or Mole %.
A saturated hydrocarbon (Alkane) with five carbon atoms in its
Pentane (C5H12)
molecule (C5H12). A liquid under normal conditions.
Pentane, Normal See Normal Pentane.
A hydrocarbon mixture consisting mostly of normal pentane and
Pentanes Plus
heavier components.
The input/output and data storage devices attached to a computer such
Peripheral as disk drives, printers, keyboards, displays, data acquisition systems,
etc.
Persistent Refers to data that remains available after a Warm Start.
PEX A flexible material used for LevelMaster sensors.
PGC Process Gas Chromatograph
A time based relationship between a periodic function and a reference.
Phase In electricity, it is expressed in angular degrees to describe the voltage
or current relationship of two alternating waveforms.
Hydrocarbon derivative containing an [OH] group bound to an aromatic
Phenol
ring.
Page B46 2101510-002 rev. AE

TERM DEFINITION
A change in which a substance changes from one physical state to
Physical Change another but no substances with different composition are formed.
Example Gas to Liquid - Solid.
Proportional, Integral, Derivative. A three mode control action where the
PID controller has time proportioning, integral (auto reset) and derivative
rate action.
A ceramic material that has piezoelectric properties similar to those of
Piezoceramic
some natural crystals.
Liquid hydrocarbons that have condensed from gas to liquid as a result
of changes in pressure and temperature as gas flows in a pipeline.
Pipeline Condensate
Pipeline condensate only remains as a liquid under high-pressure
conditions and would vaporize at atmospheric pressure.
All liquid hydrocarbons and other products (including sulfur and
Plant Products
excluding residue gas) recovered in a gas processing plant.
PLC See Programmable logic controller
A technique used to optimize gas production. A Steel plunger is
inserted into the production tubing in the well. The flow is turned off and
Plunger Lift this shut-in causes plunger to fall allowing fluid to collect above plunger.
Different techniques are used to decide how long to shut in and flow the
well.
In electricity, the quality of having two oppositely charged poles, one
Polarity
positive one negative.
Polling A snapshot view of the readings taken by the Totalflow equipment.
A communications connection on a computer or a remote controller. A
Port place of access to a device or network, used for input/output of digital
and analog signals.
Positive Temperature
An increase in resistance due to an increase in temperature.
Co-efficient
Opens circuit when high current condition occurs. Closes when
Positive Temperature
condition no longer exists. Replaces typical fuses, which require
Co-efficient Fuse
replacement when blown.
Program Organization Unit. This is Softings term for an independent
POU
programming unit. Programs, functions, etc.
A separate unit or part of a circuit that supplies power to the rest of the
Power Supply
circuit or to a system.
PPM Acronym for parts per million.
The contractual, regulatory or standard ambient pressure at which
Pressure Base natural gas is measured or sampled expressed in psia (pounds per
square inch absolute).
Pressure Differential Difference in pressure between any two points in a continuous system.
Pressure testing at different levels of pressure. Used for comparison
Pressure Markers
purposes.
2101510-002 rev. AE Page B47

TERM DEFINITION
Pressure, Absolute See PSIA.
Pressure, Atmospheric See Atmospheric Pressure.
In the natural gas industry pressure is measured by the force applied to
a designated area. PSI and OSI refer to how much pressure (pound or
Pressure, Gas ounce) is applied to one square inch. Inches Water Column (In.W.C.) is
also used to express gas pressure and is measured using a manometer
for lower pressure readings. 1 PSIG=27.21 Inches Water Column.
Pressure, Gauge See PSIG.
A cell or battery which is not intended to be recharged and is discarded
Primary Cell (or Battery)
when the cell or battery has delivered all its electrical energy.
PRM Acronym for Pressure Regulator Module.
A generic term that is used to describe many types of temperature
Probe
sensors.
Gas use for which alternate fuels are not technically feasible, such as in
Process Gas applications requiring precise temperature controls and precise flame
characteristics.
Program A list of instructions that a computer follows to perform a task.
A highly reliable special-purpose computer used in industrial monitoring
Programmable Logic and control applications. PLCs typically have proprietary programming
Controller and networking protocols, and special-purpose digital and analog I/O
ports.
Computer memory in which data can be written to. ROM is used for
Programmable Read
storing programs (e.g. operating systems) and characteristic files on a
Only Memory
permanent basis. (non-volatile)
The standard method a CPU uses to access an I/O device-- each byte
Programmed I/O
of data is read or written by the CPU.
PROM See Programmable Read Only Memory
A saturated hydrocarbon (Alkane) gas, the molecule of which is
composed of three carbon and eight hydrogen atoms. Propane is
Propane (C3H8) present in most natural gas and is the first product refined from crude
petroleum. It has many industrial uses and may be used for heating
and lighting. Contains approximately 2,500 Btu per cubic foot.
PID Controllers are designed to eliminate the need for continuous
operator attention. An example would be the cruise control in a car or a
Proportional, Integral, house thermostat. These controllers are used to automatically adjust
Derivative some variable to hold the measurement (or process variable) at the set-
point. The set-point is where you would like the measurement to be.
Error is defined as the difference between set-point and measurement.
A saturated hydrocarbon (Alkane) gas, the molecule of which is
composed of three carbon and six hydrogen atoms. At room
temperature and pressure, propylene is a gas. It is colorless, highly
Propylene (C3H6)
flammable, and has a odor similar to garlic. It is found in coal gas and
can be synthesized by cracking petroleum. The main use of propylene
is as a monomer, mostly for the production of polypropylene.
Page B48 2101510-002 rev. AE

TERM DEFINITION
A formal set of conventions governing the formatting and relative timing
Protocol
of message exchange between two communicating systems.
PSI Pounds per Square Inch.
Pounds per Square Inch Absolute. Absolute pressure uses a perfect
PSIA vacuum as the zero point. A perfect vacuum is 0 PSIA.
PSIA=PSIG + Atmospheric Pressure.
Pounds per square inch differential. Pressure difference between two
PSID
points.
Pounds per Square Inch Gauge. Gauge pressure uses the actual
PSIG
atmospheric pressure as the zero point.
Pounds per square inch standard. Pressure referenced to a standard
PSIS
atmosphere.
Physikalisch Technische Bundesanstalt (Federal Physical Technical
PTB
Office) or Technical Institute for Certification.
PTC See Positive Temperature Co-efficient Fuse.
Any digital input to a meter (usually a turbine) that is used to measure
Pulse Input pulses over a time period. This calculates volume and flow rate for each
period of time.
An operational mode used by the LevelMaster for measuring single
float levels by transmitting a pulse to the primary windings, reading the
Pulse Mode voltage level on both the primary and secondary windings and using a
calculation whereby one is subtracted from another to determine the
single fluid level.
Any digital output that is used to measure pulses over a period of time.
Pulse Output Frequency of Pulses in a predetermined time frame represents a value
to be used in calculating volume and flow rate.
RF for short. That part of the spectrum from approx. 50kHz to
Radio Frequency
gigahertz.
Electromagnetic radiation which is emitted by electrical circuits carrying
Radio Frequency rapidly changing signals, as a by-product of their normal operation, and
Interference which causes unwanted signals (interference or noise) to be induced in
other circuits.
RAM See Random Access Memory.
RAM Disk A lithium backed storage chip. Also see Random Access Memory.
RAMS Acronym for Remote Alarms Monitoring System.
Onboard read/write volatile memory, generally used for application
Random Access
variables and the file system. Data stored is lost if power is removed
Memory
(volatile).
Those values over which a transducer is intended to measure, specified
Range
by its upper and lower limits.
Rangeability The ratio of the maximum flowrate to the minimum flowrate of a meter.
2101510-002 rev. AE Page B49

TERM DEFINITION
The number of ampere-hours a cell/battery can deliver under specific
Rated Capacity
conditions (rate of discharge, cut-off voltage, temperature).
Raw Gas Natural gas that has not been processed.
A mixture of natural gas liquids that has not been fractionated or
Raw Mix Liquids
separated into its various components.
RBUS Communication abbreviation for Results Bus.
RCV Communication abbreviation for Received.
RD Acronym for Relative Density.
Refers to Totalflows SRam Drive (solid state memory chip) located on
the main board, used to store data and configuration files. The RDrive
RDrive
is a lithium backed, volatile memory chip and is not affected by a warm
start.
Computer memory in which data can be routinely read but written to
only once using special means when the ROM is manufactured. ROM
Read Only Memory
is used for storing data or programs (e.g. operating systems) on a
permanent basis.
Data acted upon immediately instead of being accumulated and
Real Time
processed at a later time.
The SCADA system has an in-memory RTDB for the data it collects
from various devices. Real-time generally means that the data is
acquired often enough that the user can make operational changes to
the process while it is still useful to do so. On a factory floor, this can be
Real Time Data Base
in milliseconds. For remote devices which may require a couple of
hours of drive time to reach, real-time can be thought of in tens of
minutes or even hours. The data base can meet either of these
requirements.
Any operating system where interrupts are guaranteed to be handled
within a certain specified maximum time, thereby making it suitable for
Real Time Operating
control of hardware in embedded systems and other time-critical
System
applications. RTOS is not a specific product but a class of operating
system.
The conversion of electrical energy, provided in the form of a current
Recharge/Charge from an external source (charger), into chemical energy within a
cell/battery.
This is the standard interface for full-duplex data communication
conducted with two way independent channels. It employs unbalanced
signaling and refers to point-to-point communications between one
Recommended driver and one receiver in a 4-wire bus system.
Standard 232
The RS-232 (single-ended) transmits at a relatively slow data rate (up
to 20K bits per second) and short distances (up to 50 Ft. @ the
maximum data rate).
Page B50 2101510-002 rev. AE

TERM DEFINITION
This is the standard interface for half-duplex communications
conducted with a dual-state driver. It employs balanced signaling and
refers to multi-drop communications between one driver and up to ten
Recommended receivers, known as straight-through cabling in a 4-wire bus system.
Standard 422
The RS-422 (Differential) transmits a much faster data rate (up to 100K
bits per second) and longer distances (up to 4000 Ft. @ the maximum
data rate).
This is the standard interface for half-duplex communications
conducted in the tri-state or common mode. It employs balanced
signaling and refers to true multi-point communications between up to
Recommended 32 drivers and 32 receivers, in 2-wire bus system.
Standard 485 The RS-485 (Differential) transmits a much faster data rate (up to 100K
bits per second) and longer distances (up to 4000 Ft. @ the maximum
data rate). It also supports more nodes per line because it uses lower
impedance drivers and receivers.
Record A collection of unrelated information that is treated as a single unit.
Register A storage device with a specific capacity, such as a bit, byte or word.
Electromechanical device containing a coil and set of contacts. The
Relay
contacts close when the coil is activated.
Not hard-wired; communicating via switched lines, such as telephone
Remote lines. Usually refers to peripheral devices that are located a site away
from the CPU.
Totalflows XSeries Remote Controller is a low power, microprocessor
Remote Controller,
based unit designed to meet a wide range of automation, monitor,
XSeries.
control, alarming and measurement applications.
An industrial data collection device similar to a PLC, designed for
Remote Terminal Unit location at a remote site, that communicates data to a host system by
using telemetry (such as radio, dial-up telephone, or leased lines).
The ability of a transducer to reproduce output readings when the same
measurement value is applied to it consecutively, under the same
Repeatability
conditions, and in the same direction. Repeatability is expressed as the
maximum difference between output readings.
The portion of natural gas remaining in a gaseous state after recovery
Residue Gas
of certain components through gas processing.
Resistance The measure of the ability of a material to pass a current.
Resistance Temperature
A relationship between a thermistors resistance and the temperature.
Characteristic
Resistant Thermal A metallic probe that measures temperature based upon its coefficient
Detector of resistivity.
Passive component with a known resistance. The value of resistance is
Resistor
usually shown by a set of colored bands on the body of the component.
The smallest significant number to which a measurement can be
Resolution determined. For example, a converter with 12-bit resolution can resolve
1 part in 4096.
2101510-002 rev. AE Page B51

TERM DEFINITION
A calculated value determined by analyzing a known substance under
precise conditions (temperature, pressure, carrier flow rate) which
equals the area of the peak divided by the weight or volume of the
Response Factor injected substance. This calculated value is then used as a response
multiplier or offset for analyzing a sample of this same substance from
another source. In the case of Natural gas, each component will have
its own Response Factor.
1) The length of time required for the output of a transducer to rise to a
specified percentage of its final value as a result of a step change of
input. 2) The time required by a sensor to reach 63.2% of a step
Response Time
change in temperature under a specified set of conditions. Five time
constants are required for the sensor to stabilize at 600 of the step
change value.
This refers to a Totalflow procedure in which all the Station or
Configuration files are restored to the SDRIVE from the file located on
Restore
the laptop. This process is very helpful prior to doing a Cold Start when
you want to continue using the Configuration and Station files.
The ratio of inertial and viscous forces in a fluid defined by the formula
Reynolds Number Re = rVD/, where: r = Density of fluid, = Viscosity in centipoise (CP),
V = Velocity, and D = Inside diameter of pipe.
RFI See Radio Frequency Interference.
A flat cable in which the conductors are side by side rather than in a
Ribbon Cable
bundle.
Natural gas which, based on its content of liquefiable hydrocarbons, is
Rich Gas
suitable for processing in a gas plant for recovery of plant products.
ROM See Read Only Memory
RRTS Communication abbreviation for Remote Ready To Send.
RS-232 See Recommended Standard 232.
RT See Runtime.
RTD See Resistant Temperature Detector.
RTDB See Real Time Data Base.
RTOS See Real Time Operating System.
RTS Communication abbreviation for Ready To Send.
RTU See Remote Terminal Unit
The time required for an acoustic signal to travel from point A to point
Runtime B. This measurement is used in calculating the speed of Sound, gas
velocity and volume in the TotalSonic Meter.
RXD Communication abbreviation for Receive Data.
Page B52 2101510-002 rev. AE

TERM DEFINITION
Serial Number. The whole Serial Number is made up of a prefix of 5
S/N
digits and the suffix, a 10 digit configuration number.
S1 Sample Line 1 (located on NGC8200 series Feed-Through Assembly).
A fitted plate held in place by clamps, straps, heat fusion, or welding
over a hole punched or drilled in a gas main to which a branch line or
Saddle
service line connection is made. The saddle also may serve as a
reinforcing member for repair.
A tube with a given volume used in conjunction with a valve for
Sample Loop measuring and holding the sample gas before pushing it into the
chromatograph column.
Saturated BTU The heating value of natural gas that is saturated with water vapor.
Hydrocarbons that contain only single bonds. They are also called
Saturated Hydrocarbons
Alkanes or paraffin hydrocarbons.
This refers to a Totalflow procedure in which all the Station or
Save Configuration files are copied from the RDRIVE or the SDRIVE, to a file
created on a laptop.
Digital Signal Smoothing. A special class of a digital signal processing
Savitsky-Golay
filter. Specifically determines the coefficients that are used for signal
Smoothing
processing.
SCADA See Supervisory Control and Data Acquisition
Abbreviation for one standard cubic foot, a measurement of a gas
Scf volume at a contractual, regulatory or standard specified temperature
and pressure.
Schematic Another name for a circuit diagram.
SCM Acronym for Sample Conditioning Module.
To move all or part of the screen material up to down, left or right, to
Scroll
allow new information to appear.
SD Card Secure Digital Card.
Totalflows Serial E2 PROM solid state memory chip, located on the
SDRIVE Main Board (volatile memory, affected by a cold start), used to store
configuration or station files.
Selectable measurement units for various international and specialized
Selectable Units
application needs.
A property of a DAQ board that has an extremely stable onboard
Self-Calibrating reference and calibrates its own A/D and D/A circuits without manual
adjustments by the user.
Material that is nether a conductor nor insulator. Its properties can be
Semiconductor
altered by a control voltage.
2101510-002 rev. AE Page B53

TERM DEFINITION
That part of the transducer which reacts directly in response to the
Sensing Element
input.
A device that responds to a physical stimulus (heat, light, sound,
Sensor pressure, motion, flow, and so on), and produces a corresponding
electrical signal.
The Sensor File contains all the setup/calibration information of the unit.
The Sensor File is a (.dat) file and by default is named after the base
Sensor File serial number proceeded by an "s", such as s00108.dat. Although the
name can be overwritten, it is recommended that the default name be
kept.
A common form of data transmission, in which the bits of each
Serial I/O
character are sent one at a time over the line.
A communications interface that uses one data line to transfer data bits
sequentially. On the IBM PC the serial port refers to a standard
Serial Port
asynchronous serial interface which uses the 8250/16450/16550 family
of UARTs.
The period of useful life (usually in hours or minutes) of a primary
Service Life
cell/battery before a predetermined cut-off voltage is reached.
Set Point The temperature at which a controller is set to control a system.
Set-Point A "level" or control point in a feedback system.
SFC Sequential Function Chart (IEC supported programming language)
SG Acronym for Specific Gravity.
A connection of comparatively low resistance accidentally or
intentionally made between points on a circuit between which the
Short Circuit
resistance is normally much greater. Also called a "bridge" or "short"
such as when solder from two tracks touch on a PC board.
The reduction in volume and/or heating value of a natural gas stream
Shrinkage
due to extraction or removal of some of its components.
SIG See Signal.
Any communication between message-based devices consisting of a
Signal
write to a signal register.
Signal Generator A circuit that produces a variable and controllable signal.
Can represent a number half the size of a unsigned integer, including
Signed Integer
a negative number.
Sink Device such as a load that consumes power or conducts away heat.
Extra Daily records for recording events that require the start of a new
Skip Days day. i.e. Volume Reset, Backward Time change over the hour, and
Contract Hour change.
SNAM Italys Certification Board
SNR Signal to Noise Ratio.
SoftCONTROL Softings IEC compiler environment
Page B54 2101510-002 rev. AE

TERM DEFINITION
Softing Maker and distributor of the IEC compiler softCONTROL
The non-physical parts of a computer system that include computer
Software programs such as the operating system, high-level languages,
applications programs, etc.
Solar cell A cell that produces current under sunlight.
A coil of wire that is long compared to its diameter, through which a
Solenoid current will flow and produce a magnetic flux to push or pull a rod
(called an armature).
SOS See Speed of Sound.
Sour Gas Natural gas that has a high concentration of H2S.
Source Device that provides signal power or energy to a load.
SP See Static Pressure
The difference between the upper and lower limits of a range
Span
expressed in the same units as the range.
The ratio of the mass of a solid or liquid to the mass of an equal volume
of distilled water at 4C (39F) or of a gas to an equal volume of air or
Specific Gravity
hydrogen under prescribed conditions of temperature and pressure.
Also called relative density.
Rate at which gas travels through the pipeline. Used in flow calculations
Speed of Gas
in the TotalSonic Meter. Calculations follow AGA 9 Report.
Rate at which sound travels through the medium. Used in flow
Speed of Sound calculations in the TotalSonic Meter. Calculations follow AGA 10
Report.
SPU Signal Processing Unit (measurement transducer).
SQL See Structured Query Language.
SRAM See Static Random Access Memory
SSM Acronym for Stream Selector Module.
ST Structured Text (IEC supported programming language)
The quality of an instrument or sensor to maintain a consistent output
Stability
when a constant input is applied.
Is a vapor containing less than 0.1 PPM of liquid when vapor is cooled
Stable Gas to 18.3F (10C) below the coldest ambient temperature possible at any
point in the system.
Equals PSIA or PSIG. Referenced to atmospheric pressure versus
absolute pressure in a vacuum. It is defined as the pressure exerted by
Static Pressure
a non-moving liquid or gas. In the case of a gas well this would be the
natural PSI of the gas inside of the well.
The place in your computer that programs reside when running. You
Static Random Access can access any part of the memory, and it can easily be overwritten
Memory with new values. SRAM is much more expensive and physically larger
than DRAM but much faster.
2101510-002 rev. AE Page B55

TERM DEFINITION
Any digital output that uses On or Off conditions to determine the
Status Output status of the assigned description. Changing from one to the other
represents a change in the condition.
STP Standard Temperature and Pressure
IBM developed this language in the 60s as a way of accessing data
from a relational database. It has a very simple syntax for simple
functions but can become complex for sophisticated applications. This
language is standardized by international standards bodies, and is
Structured Query
almost universal in application. Almost all databases support SQL. The
Language
RTDB supports SQL and this makes it extremely flexible within a
corporate network. Authorized users throughout the organization can
write SQL statements to acquire data from this database that they need
for Marketing, Accounting, Engineering, or other functions.
A pale, yellow, non-metallic chemical element that may be found in a
Sulfur gas stream and which needs to be removed or reduced from the gas
stream for corrosion control or health or safety reasons.
A factor used to account for the following effect: Boyle's law for gases
states that the specific weight of a gas is directly proportional to the
absolute pressure, the temperature remaining constant. All gases
deviate from this law by varying amounts, and within the range of
conditions ordinarily encountered in the natural gas industry, the actual
Supercompressibility specific weight under the higher pressure is usually greater than the
Factor theoretical. The factor used to reflect this deviation from the ideal gas
law in gas measurement with an orifice meter is called the
"Supercompressibility factor Fpv". The factor is used to calculate
corrected from volumes at standard temperatures and pressures. The
factor is of increasing importance at high pressures and low
temperatures.
A common PC function in process control applications, where
Supervisory Control and
programmable logic controllers (PLCs) perform control functions but are
Data Acquisition
monitored and supervised by a PC.
A sudden change (usually an increase) in the voltage on a power line.
Surge
A surge is similar to a spike, but is of longer duration.
SV Sample Vent (located on NGC8200 series Feed-Through Assembly).
SW VBATT Switched Battery Voltage. Cycles power to equipment to save power.
An electrical device for connecting and disconnecting power to a circuit,
Switch having two states, on (closed) or off (open). Ideally having zero
impedance when closed and infinite impedance when open.
(1) Hardware - A property of an event that is synchronized to a
Synchronous reference clock. (2) Software - A property of a function that begins an
operation and returns only when the operation is complete.
Comparable to the grammar of a human language, syntax is the set of
Syntax rules used for forming statements in a particular programming
language.
Page B56 2101510-002 rev. AE

TERM DEFINITION
A measure of the amount of noise seen by an analog circuit or an ADC
System Noise
when the analog inputs are grounded.
TankMaster Totalflow Control System for LevelMaster Tank Units.
To cut threads in a round hole so that other fittings or equipment can be
Tap
screwed into the hole. Also to make an opening in a vessel or pipe.
TBUS Communication abbreviation for Transmit Bus.
TCD See Thermal Conductivity Detector.
TCP/IP This is the basic communication format for the Internet, and
for much of what happens on a corporate network. Virtually all
networked PCs and other computers have an IP address having the
format xxx.xxx.xxx.xxx (xxx can range from 0 to 255 in most cases).
You can see the IP address of your PC by going to the start menu,
TCP/IP
selecting run, and entering cmd. A DOS Box will be displayed on your
screen. Type ipconfig to get the IP address. When you enter a URL
(e.g., www.totalflow.com) in a browser, a DNS server (on the network)
resolves this into an IP address and directs your request to the machine
with that address.
TCR Temperature Compensated Regulator.
Totalflow DDE Server that allows Microsoft Windows applications with
TDS32 DDE capabilities to communicate with Totalflows equipment. For
example data can be retrieved and placed in an Excel spreadsheet.
An experimental number used to modify the calibration of a device
Temperature Coefficient (Totalflow transducer) to account for changes in environmental
temperature.
The maximum change in output, at any measured value within the
Temperature Error specified range, when the transducer temperature is changed from
room temperature to specified temperature extremes.
The range of ambient temperatures within which all tolerances specified
Temperature Range,
for Thermal Zero Shift and Thermal Sensitivity Shift are applicable
Compensated
(temperature error).
The temperature of the air, atmosphere or other fluid that completely
surrounds the apparatus, equipment or the work piece under
consideration. For devices which do not generate heat, this
temperature is the same as the temperature of the medium at the point
of device location when the device is not present. For devices which do
Temperature, Ambient
generate heat, this temperature is the temperature of the medium
surrounding the device when the device is present and generating heat.
Allowable ambient-temperature limits are based on the assumption that
the device in question is not exposed to significant radiant-energy
sources such as sunlight or heated surfaces.
Temperature, Flowing Temperature of the flowing fluid. Usually gas and measured by an RTD.
Man-Machine interface tool used as and engineering interface with
Terminal Mode
equipment.
Termination Placement of a connector on a cable.
2101510-002 rev. AE Page B57

TERM DEFINITION
The NGC8200s termination panel acts as a connection to the outside
world. It features transient protection, a voltage regulator for the digital
controller, positive temperature co-efficient fuses (PTC) and many other
Termination Panel safeguards to protect the remainder of the system from electrical
damage. All outside communications and I/O are channeled through
this board. It is designed to be a low cost, field replaceable
maintenance solution and is designed to operate on either 12V or 24V.
A circuit board with screw terminals or other connector system that
Termination Panel allows convenient connection of field signals to a data acquisition or
communication system.
In PCCU32, the 32-Bit XSeries Loader is the program that allows for
the downloading of specific files to an NGC, XFC, XRC or FLO
XSeries device. The 32-Bit XSeries Loader application allows packages
containing a combination of Flash, WinCE OS (nk.bin), ISaGraf
Runtime, Blackfin Firmware (NGC) and configuration files to be
TF Loader Packages downloaded to XFCs, XRCs, NGCs or FLO machine types. These
same packages can be downloaded to other machines of the same
type to expedite configurations for machines having the same purpose.
With the creation of these packages, the user is then prevented from
accidentally loading incompatible packages to the wrong device.
TF.NET Totalflow network used to access web data.

TFIO Module Totalflow Input/Output module (i.e. quad AO)
Universal detector that shows a response to all compounds. An
electrical component that changes resistance based on the
Thermal Conductivity components ability to conduct heat. In chromatography, two TCDs are
Detector used, 1)as a reference detector and 2) as the sensor detector. The
reference detector is exposed to only the carrier gas and the Sensor
detector is exposed to the sample.
A temperature-sensing element composed of sintered semiconductor
material which exhibits a large change in resistance proportional to a
Thermistor
small change in temperature. Thermistors usually have negative
temperature coefficients.
Thermistor Bead See Thermal Conductivity Detector.
A temperature sensor created by joining two dissimilar metals. The
Thermocouple
junction produces a small voltage as a function of the temperature.
A closed-end tube designed to protect temperature sensors from harsh
environments, high pressure, and flows. They can be installed into a
Thermowell system by pipe thread or welded flange and are usually made of
corrosion-resistant metal or ceramic material depending upon the
application.
Therms Master Totalflow application for Gas Analyzer.
The allowable percentage variation of any component from that stated
Tolerance
on its body.
Page B58 2101510-002 rev. AE

TERM DEFINITION
Product line of ABB Inc. Maker and distributor of the XSeries Flow
Totalflow
Computers (XFC) and Remote Controllers (XRC).
TotalSonics Man Machine Interface software program. May also be
TotalSonic MMI
called MEPAFLOW 600.
A device for converting energy from one form to another, specifically
Transducer the measurement of pressure differential in natural gas gate stations.
I.e. Pressure to voltage or current.
The rate, measured in bytes/s, at which data is moved from source to
Transfer Rate destination after software initialization and set up operations; the
maximum rate at which the hardware can operate.
An abrupt change in voltage, of short duration (e.g. a brief pulse
Transient
caused by the operation of a switch).
A three leaded device (Collector, Base, Emitter) used for amplifying or
Transistor switching. Also called a bi-polar transistor to distinguish it from Field
Effect Transistor etc.
A device that converts audio, video or coded signals into modulated
Transmitter radio frequency signals which can be propagated by electromagnetic
waves (radio waves).
Tranzorb Transient Voltage Suppression device.
Tank Request Block Editor. When requesting storage space after
TRB
adding a LevelMaster application, the file is saved as a *.trb file.
Cylinder for transporting or storing liquids: any long hollow cylinder
Tube
used to transport or store liquids.
An amplitude modulated (AM) receiver with one or more stages of radio
Tuned Radio Frequency
frequency before the detector.
TXD Communication abbreviation for Transmit Data.
UDINT Unsigned Double Integer
Underwriters Laboratories, Inc. An independent laboratory that
UL
establishes standards for commercial and industrial products.
A form of pipe fitting where two extension pipes are joined at a
Union
separable coupling.
An external peripheral interface standard for communication between a
computer and external peripherals over a cable using biserial
Universal Serial Bus
transmission. It supports both isochronous and asynchronous data
transfers.
Is a calculation of the Peak Area divided by the Response Factor for
Unnormalized Total
each component, then summed by each component.
Can represent a number twice the size of a signed integer, but cannot
Unsigned Integer
represent a large negative number.
This refers to a Totalflow procedure in which any file(s) located in the
Upload on-board memory of a Totalflow Host is copied to a file created on a
laptop PC.
2101510-002 rev. AE Page B59

TERM DEFINITION
Un-interruptible power supply. A power conditioning unit placed
between the commercial power service and the protected device. The
UPS UPS uses line power to charge batteries, which, in the case of a power
failure, can drive electronic circuitry to produce the appropriate AC
requirements for some time period.
Oil and natural gas exploration and production activities; plus gas
Upstream
gathering, processing and marketing operations.
The first pipeline to transport natural gas en route to an inter-connect
Upstream Pipeline
point for delivery to another pipeline. See DOWNSTREAM PIPELINE.
USB Acronym for Universal Serial Bus.
Generally refers to the peripheral device (Slave or Client) that is driven
USB Client by a computer (Master or Host). Examples are a printer and digital
camera.
Generally refers to the computer device (Master or Host) that drives a
USB Host peripheral piece of equipment (Slave or Client). An example is a Laptop
or Desktop Computer.
USX Provider of the RTOS used by the XSeries product line
VAC Volts of alternating current.
A pressure less than atmospheric pressure, measured either from the
Vacuum
base of zero pressure or from the base of atmospheric pressure (PSIA).
A mechanical device for controlling the flow of fluids and gases; types
Valve
such as gate, ball, globe, needle, and plug valves are used.
This feature provides automatic feedback control of Differential
Pressure (DP), Static Pressure (SP), and Flow Rate for the purpose of
Valve Control
positioning a flow valve to maintain a desired value of DP, SP, or Flow
Rate.
The pressure exerted by a liquid when confined in a specified tank or
Vapor Pressure
test apparatus.
Totalflows Voice Alarm System. A software program that receives and
VAS32
transmits alarm notifications via cell, telephone or pager systems.
VBATT Battery Voltage. The voltage output from the battery source.
VCI Valve Control Interface.
VDC Volts of direct current.
Verband der Elektrotechnik Elektronik Informationstechnik [Association
VDE
for Electrical, Electronic & Information Technologies]
Velocity The time rate of change of displacement; dx/dt.
A normally sealed mechanism which allows for the controlled escape of
Vent
gases from within a cell.
VGA Video Graphic Array.
Page B60 2101510-002 rev. AE

TERM DEFINITION
A method of making disk storage appear like RAM memory to the CPU,
Virtual Memory thus allowing programs that need more RAM memory than is installed
to run in the system. This technique is slow compared to "real" memory.
Viscosity The inherent resistance of a substance to flow.
VOG Velocity of Gas.
Volatile Memory A storage medium that loses all data when power is removed.
Volt The unit of voltage or potential difference.. One thousand volts = 1kV.
Electrical pressure, the force, which causes current to flow through a
conductor. Voltage must be expressed as a difference of potential
between two points since it is a relational term. Connecting both
Voltage
voltmeter leads to the same point will show no voltage present although
the voltage between that point and ground may be hundred or
thousands of volts.
Voltmeter A meter for reading voltage. It is one of the ranges in a multimeter.
Volume Calculation
The specified length between reading and calculating volume data.
Period
Calculated using the area of the full closed conduit and the average
fluid velocity in the form, Q = V x A, to arrive at the total volume quantity
Volume Flow Rate
of flow. Q = volumetric flowrate, V = average fluid velocity, and A =
cross sectional area of the pipe.
VOS Velocity of Sound.
A rebooting technique which will clear most operational errors, without
Warm Start damaging either the data or configuration files. This causes the
equipment to boot from the Rdrive, which is a solid state memory chip.
Symbol W. The unit of power. One watt is the product of one volt and
Watt
one amp. Power (W) = Current (I) X Energy (E). (E = Volts)
The distance between two points of corresponding phase in
Wavelength
consecutive cycles
All the text, graphics, and sound visible with a single access to a Web
Web Page
site; what you see when you request a particular URL.
The hardware and software required to make Web pages available for
Web Server
delivery to others on networks connected with yours.
Web Site A collection of electronic "pages" of information on a Web server
Well, Development A well drilled in order to obtain production of gas or oil known to exist.
A deep well in which to inject waste chemicals, etc., such as a well to
Well, Disposal dispose of salt brine from the solution mining of salt dome gas storage
caverns.
A well drilled to a previously untested geologic structure to determine
Well, Exploratory
the presence of oil or gas.
A well which produces at surface conditions the contents of a gas
Well, Gas
reservoir; legal definitions vary among the states.
2101510-002 rev. AE Page B61

TERM DEFINITION
A well which is producing oil or gas at such a low rate that it may not
Well, Marginal
pay for the drilling.
Non-associated gas well capable of producing no more than 90
Well, Stripper
Mcf/day at its maximum rate of flow.
An exploratory well being drilled in unproven territory, that is, in a
Well, Wildcat
horizon from which there is no production in the general area.
The assembly of fittings, valves, and controls located at the surface and
Wellhead connected to the flow lines, tubing, and Casing of the well so as to
control the flow from the reservoir.
Product line designed to communicate RS-485 without the use of
WellTell Wireless cabling. Group consists of the wireless host (WellTell-X), wireless IS
client (WellTell-IS) and wireless IO client (WellTell-IO).
WellTell-IO Client communication device designed with extra on-board IO.
WellTell-IS Client communication device designed with an intrinsically safe barrier.
WellTell-X Host communication device for WTW product line.
Circuit design using two TCDs to measure components in
Wheatstone Bridge
chromatography.
Windows Central Collection Unit. Windows version of software to
WINCCU process, archive and manipulate data collected from the Totalflow
products.
In computer graphics, a defined area in a system not bounded by any
Window
limits; unlimited "space" in graphics.
In the field, where hydrocarbons are changing hands and actual cash
register transactions being performed, it is not uncommon for one party
Witness or the other to request / require a representative or company employee
be present during calibrations and or routine maintenance. Often this
arrangement is contractually linked.
Calculated from the energy content, or a higher heating value of the
Wobbe Index
gas, and the relative density of the gas (Btu/RD1/2).
A number proportional to the heat input to a burner at constant
pressure. In British practice, it is the gross heating value of a gas
Wobbe Number divided by the square root of its gravity. Widely used in Europe,
together with a measured or calculated flame speed, to determine
interchangeability of fuel gases.
The highest voltage that should be applied to a product in normal use,
Working Voltage normally well under the breakdown voltage for safety margin. See also
Breakdown Voltage.
An Internet service facilitating access to electronic information - also
World Wide Web
known as the Web, WWW, or W3.
Write To record data in a storage device or on a data medium.
WTW WellTell Wireless product line. See WellTell Wireless.
XDCR See External Transducer.
Page B62 2101510-002 rev. AE

TERM DEFINITION
XFC See Flow Computer, XSeries.
Totalflows new Generation 4 extendable XFC equipment featuring
XFC G4
technology that is expandable and flexible for ever changing needs.
The main electronic board used in XSeries flow computers. The XFC-
XFC-195 Board
195 Board mounts on the inside of the enclosures front door.
Totalflows Class 1 Div 1 Flow Computer. This Totalflow Flow Computer
XFC6200EX is housed in an explosion proof housing and has similar operational
features as the FLO, with additional capabilities.
XIMV See XSeries Integral Multivariable Transducer.
XMV See Multivariable Transducer.
XRC XSeries Remote Controller. Also see Remote Controller, XSeries.
Totalflows new Generation 4 extendable XRC equipment featuring
XRC G4
technology that is expandable and flexible for ever changing needs.
Totalflows new extendable equipment series featuring technology that
XSeries
is expandable and flexible for ever changing needs.
Abbreviated XIMV. A smart Multivariable Transducer that is an integral
part of the XSeries Flow Computer, measuring Static Pressure (SP),
Differential Pressure (DP) and Flowing Temperature (Tf). This refers to
XSeries Integral
both the transducer portion of the device and the circuitry required to
Multivariable
supply measurements to the Main Processor Board, which is housed in
a factory sealed unit. See Multivariable Transducer for more
information.
Y Expansion factor.
Zero Gas Gas at atmospheric pressure.
The difference expressed in degrees between true zero and an
Zero Offset
indication given by a measuring instrument.
2101510-002 rev. AE Page B63

B
Bllaannkk P
Paaggee
Page B64 2101510-002 rev. AE

APPENDIX C DRAWINGS
This section of the manual has been provided as a location for
the user to place the drawings that accompanies the new
Totalflow unit.
Totalflow recommends that a complete set of all drawings that
accompany a unit be placed in this section. This would ensure
that the user have only drawings applicable to their units and
drawings that are the latest revision.
2101510-002 rev. AE Page C1

B
Bllaannkk P
Paaggee
Page C2 2101510-002 rev. AE

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2101510-002 rev.

Intended to draw attention to useful information or to clarify a

Intended to draw attention to a fact that may be useful or

Intended to draw your attention to information regarding

Intended to draw attention to a statement that might keep the

Indicates procedures that are only valid if system design

Safety Practices and Precautions

Various statements in this manual, identified as conditions or practices that could

Protective ground (earth) terminal.

Grounding the Product

If a grounding conductor is required, it should be connected to the grounding

Danger From Loss of Ground

A grounding conductor may or may not be required depending on the hazardous

If it is determined that the equipment cannot be operated safety, it should be taken

1.1 System Overview

Based on ABB Totalflow XSeries technology, the NGC features a common

1.1.3 Typical Installation

2101510-002 rev. AE Page 11

Figure 11 Typical Single Stream Installation

STREAM 2 SAMPLE PROBE

Figure 12 Typical Multi-Stream Installation

Molecular Common Abbreviation Component Boiling Point

Page 14 2101510-002 rev. AE

Table 12 System Specifications

2101510-002 rev. AE Page 15

Figure 13 Modular Design NGC8206

Page 16 2101510-002 rev. AE

1.3.3 Cast Aluminum Enclosure

The custom designed, explosion proof enclosure consists of a cylindrical shaped

1.3.3.1 Exterior Hubs

2101510-002 rev. AE Page 17

Figure 15 NGC8206 Enclosure Left Side

Page 18 2101510-002 rev. AE

Figure 17 NGC8206 Enclosure Underside

1.3.4 Feed-through Assembly (2102026-xxx)

2101510-002 rev. AE Page 19

Figure 18 NGC Feed-through Assembly (2102026-xxx)

The 0.5 micron Filters should NOT be considered as a

1.3.5 Analytical Module

Page 110 2101510-002 rev. AE

Figure 19 Analytical Module

2101510-002 rev. AE Page 111

Figure 110 Manifold Assembly

1.3.5.3 Analytical Processor Assembly

Page 112 2101510-002 rev. AE

2101510-002 rev. AE Page 113

1.3.6 Digital Controller Assembly

Page 114 2101510-002 rev. AE

Figure 113 Digital Controller Assembly with Optional Display

1.3.7 Termination Panel

2101510-002 rev. AE Page 115

USB CLIENT RECEPTICAL

Figure 114 Termination Panel

1.4 Grounding the NGC

1.4.1 Power Supply

1.4.2 Sample Probe

Page 116 2101510-002 rev. AE

2101510-002 rev. AE Page 117

1.5 Calibration/Validation Stream

Table 13 Calibration Gas Blend Recommended Components

Component Abbreviation Mol % Component Abbreviation Mol %

Methane C1 89.570 Neo Pentane Neo C5 0.100

Carbon Dioxide CO2 1.000 Iso Pentane IC5 0.100